Packaging object supplying apparatus, box body supplying apparatus, boxing apparatus, packaging system and packaging method

ABSTRACT

A packaging object supplying apparatus for supplying a packaging object to a packaging unit for packaging the packaging object into a predetermined fashion and specifically, a packaging object supplying apparatus comprising a packaging object combining portion for forming a combination of the packaging objects by combining two or more kinds of the packaging objects by a predetermined quantity in a predetermined array and a packaging object introducing portion for introducing the packaging objects combined by the packaging object combining portion to the packaging unit, a boxing apparatus comprising foldable box body supplying means, opening forming means, box body holding means, packaging object loading means, and lid forming means, a box body supplying apparatus for supplying a box body to the boxing apparatus.

This is a divisional of application Ser. No. 10/434,467 filed May 9,2003. The entire disclosures of prior application Ser. No. 10/434,467,claiming the benefit of JP 2002-134360, filed May 9, 2002, JP2002-198947, filed Jul. 8, 2002, JP 2002-352066, filed Dec. 4, 2002, JP2003-58188, filed Mar. 5, 2003, JP 2003-88083, filed Mar. 27, 2003 andJP 2003-126240, filed May 1, 2003 are all hereby incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a packaging object supplying apparatus,box body supplying apparatus, boxing apparatus, packaging system andpackaging method and particularly to a packaging object supplyingapparatus for supplying two or more kinds of packaging objects to thepackaging unit in a predetermined array, a box body supplying apparatuscapable of treating boxes of various sizes and shapes with singleequipment, a boxing apparatus having the box body supplying apparatusand a packaging system capable of automatically packing small boxes ofvarious shapes and sizes into corrugated board boxes according to apredetermined pattern.

2. Description of the Related Art

Usually, a film cartridge containing a photographic roll film isincorporated in a plastic film case and the film case is sold in a formof a carton which is a sack carton made of coated board.

Although conventionally, a carton generally adopts a small box type inwhich one film case is accommodated in each small box, recently,production number of a package so-called multi-small box type package inwhich two or more film cases are accommodated therein have increased.

A small box with a single film-type package is a standard packagingstyle for a film cartridge and its production amount is large with asmall deflection in its quantity. Thus, a small box with a singlefilm-type package can be automatically manufactured.

On the other hand, as for a multi-small box type-package, althoughproduction amount for one packaging style is not so large, there is ahuge deflection in production quantity between different packagingstyles. Further, this type has various packaging styles depending on thequantity of the film cases accommodated therein, presence/absence of aheader which is a tab-like member and position thereof.

Therefore, it is difficult to manufacture a multi-small box type-packageautomatically and thus, packages of this type often are manufactured byhand or a semi-automatic packaging machine. Therefore, there is such aproblem that its production efficiency is not raised.

Although conventionally, a packaging unit capable of coping with variousstyles of the multi-small boxes has been demanded, there are followingproblems in realizing such kind of packaging unit.

(1) Sack cartons used for the conventional multi-small box, that is,small boxes made of coated board are separated into two types; a type inwhich a film case is loaded from opening portions on both ends, and atype in which a film case is loaded from an opening portion on the sideface thereof. A cartoner, which is a packaging unit for packaging thefilm case in the sack carton, cannot cope with two kinds of the sackcartons easily.

(2) In a conventional multi-small box, bar code sizes and printingpositions are not made uniform.

(3) Even among multi-small boxes in which the same number of film casesare loaded, there is a difference in header positions and sizes.

(4) Multi-small boxes are often gathered together in a specified numberand shrink-packaged. Upon shrink packaging, the multi-small box needs tobe assembled in a different pattern in accordance with apresence/absence of its mount paper, header position, size, number offilm cases loaded therein and the like.

(5) When the multi-small boxes are packaged in a corrugated board box,they need to be packaged in a different pattern in accordance with apackaging style of the multi-small boxes.

Among the above-described problems, it is considered the problem (1) andthe problem (2) can be solved by making uniform the direction of loadingthe film cases in the sack carton and unifying the size and printingposition of the bar code to be printed on the multi-small box.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a packaging systemcapable of solving the problems (3) to (5) and a corrugated board boxfor use in the packaging system.

Another object of the invention is to provide a packaging system and apackaging method by which packed products can be manufactured in a shortperiod, which are efficient in there is no need of maintaining a largestock in manufacturing process, and which facilitates tracking if adefect is found in any package.

Still another object of the invention is to provide a packaging objectsupplying apparatus available for establishing a packaging systemcorresponding to a packaging configuration in which two or more kinds ofplastic case packed products are loaded into a carton and a packagingsystem having the packaging object supplying apparatus and capable ofcorresponding to the packaging configuration.

To achieve the above-described objects, according to a first aspect,there is provided a packaging object supplying apparatus for supplyingpackaging objects to a packaging unit for packaging in a predeterminedfashion, comprising: a packaging object combining portion for forming acombination of the packaging objects by combining two or more kinds ofthe packaging objects by a predetermined quantity thereof in apredetermined arrangement; and a packaging object introducing portionfor introducing the packaging objects combined by the packaging objectcombining portion to the packaging unit.

An example in which three kinds of packaging objects, A, B, and C arepackaged in an array of ABC by the packaging unit will be describedbelow.

Each of the packaging objects A, B and C is introduced into thepackaging object arraying portion.

The packaging object arraying portion arrays the introduced packagingobjects A, B and C in the array of ABC.

The packaging object introducing portion introduces the packagingobjects A, B and C arrayed in the order of ABC to the packaging unitwhile maintaining the array of ABC.

Because the packaging unit packages the packaging objects A, B and Carranged in the array of ABC, the packaging objects A, B and C arepackaged in an order of ABC.

It is permissible to introduce the packaging object into a small chamberin the packaging object combining portion, combine them into apredetermined array in the small chamber and introduce them into thepackaging object introduction portion or it is permissible to form thatcombination by introducing the packaging objects to the packaging objectintroducing portion according to a predetermined array.

To achieve the above-described object, according to a second aspect ofthe invention, there is provided a boxing apparatus wherein a box bodyhaving folding portions, which are developed to form a rectangularparallelepiped-shaped structure, and having flap portions for forming anopening portion and a lid portion for covering the opening portion onboth ends is constructed from a folded state so as to form the openingportions, with the box body having the opening portions held such thatone of the opening portion faces upward while the other one facesdownward, a packaging object is loaded into the main body through one ofthe opening portion and the flap portions are constructed to form thelid so that the packaging object is packaged in the box, the boxingapparatus comprising foldable box body supplying means, opening formingmeans, box body holding means, packaging object loading means and lidforming means, wherein: the foldable box body supplying meansaccommodates the box body in a folded state and supplying theaccommodated box body to the box body holding means one by one, theopening forming means constructing a box body supplied by the foldablebox body supplying means to the box body holding means from a foldedstate to form the opening portion, the box body holding means holdingthe foldable box body having the opening portion formed at the openingforming portion with one of the opening portions facing upward while theother one facing downward, the packaging object loading means loadingthe packaging object through an opening portion of the box body held bythe box body supplying means, the lid forming means folding the flapportions of the foldable box body after the packaging object is loadedinto the packaging object loading means, so as to form a lid portion forcovering the opening portion.

In the above-described boxing apparatus, the box body accommodated inthe folding condition by the foldable box body supplying means is openedby the opening forming means and then supplied to the box body holdingmeans. Therefore, after the opening is formed, the box body is held bythe box body holding means such that one of the opening portion facesupward while the other opening portion faces downward. Then, thepackaging object loading means loads the packaging object into the boxbody and the lid portion is formed by the lid forming means and finally,the packaging object is packed into the box body.

In this way, the boxing apparatus is capable of automatically carryingout a sequential processing of formation of the opening in the box body,loading of the packaging object and formation of the lid portion.

According to a third aspect of the invention, there is provided a boxbody supplying apparatus for supplying the box body to the boxingapparatus, wherein the foldable box body supplying means comprises afoldable box body accommodating portion which accommodates the box bodyin a folded state and has a box body pickup port for picking up theaccommodated box body at an end thereof and a box body supplying portionfor supplying a box body accommodated in the foldable box bodyaccommodating portion to the boxing apparatus one by one, the box bodysupplying portion comprising: box body holding means for holding the boxbody and capable of approaching/leaving the box body pickup port and theboxing apparatus; and box body moving means for moving the box bodyholding means between a box body pickup position for picking up the boxbody from the box body pickup port and a box body loading position inwhich the picked up box body is loaded on the boxing apparatus.

In the box body supplying apparatus of the present aspect, the box bodyholding means located at the box body pickup position approaches the boxbody pickup port and picks up the box body accommodated in the foldablebox body accommodating portion from the box body pickup port. The boxbody holding means is moved from the box body pickup port to the boxbody loading position by the box body moving means while holding thepicked up box body. After the box body holding means is moved to the boxbody loading position, it approaches the boxing apparatus and loads theheld box body on the boxing apparatus.

The box body supplying apparatus automatically carries out all scanningfrom pick-up of the box body to loading on the boxing apparatus.

According to a fourth aspect of the invention, there is provided apackaging system comprising: a small box package forming portion forforming a small box package in which one or multiple packaging objectsis/are accommodated in the small box thereof; an assembly formingportion for forming a small box assembly by assembling according to anassembly pattern indicating the presence/absence, position and size of aheader of the small box package and the size of the small box package;and an exterior packaging forming portion for forming an exteriorpackaging by loading the small box assembly into an exterior packagingbox according to a predetermined loading pattern set depending on theassembly pattern.

In the packaging system of the present aspect, the assembly formingportion assembles a predetermined quantity of the small boxes, forexample, five small boxes into a predetermined fashion according to theassembling pattern. The exterior packaging forming portion loads thesmall box assembly into the exterior packaging box according to apredetermined loading pattern.

The small box mentioned here includes a small box of a type having aheader which is a tab-like member, a small box of a type having noheader, a small box of a type in which the header is provided on anedge, a small box of a type in which the header is provided on a sideedge, a small box of a type in which the width of the header is equal tothat of the small box, a small box of a type in which the width of theheader is larger than that of the small box, a small box of a typeaccommodating only a packaging object such as a film case therein, asmall box of a type accommodating two or more packaging objects and thelike.

However, by the packaging system of the present aspect, small boxes canbe automatically accommodated in the exterior packaging box according tothe packaging pattern in accordance with absence/presence of a header,position and size of the header and the size of the small boxesthemselves.

According to a fifth aspect of the invention, there is provided acorrugated board box comprising a rectangular parallelepiped-shaped boxbody including a rectangular bottom portion and four side plates formedcontinuously with the bottom portion at each side of the bottom portion,with a top face of the box body being open, an intermediate partitionfor dividing the interior of the box body into two sections and fourflap portions formed continuously from the side plates along top edgesof the four side plates and folded inward along the continuous portionsso as to form lid portions for covering the open top face, theintermediate partition being fixed at an inside face of one side platethrough an end portion thereof and extending toward another side plateopposing the one side plate, so that the other end is formed as a freeend.

The corrugated board box has a partition. Therefore, when shrinkpackages are loaded, the positions of the loaded shrink packages arestabilized and the shrink packages never move laterally in thecorrugated board box. Thus, the shrink packages never interfere witheach other to be damaged.

Because the front end of the partition is free, if the assembly loadingmeans of the packaging system contacts the partition during loading ofthe small box assembly or the shrink package, the partition is movedwith little resistance. Then, as the small box assembly is loaded onboth sides of the partition, the partition is moved to the centralportion of the corrugated board box. Therefore, if the corrugated boardbox is employed in a packaging system which uses a multi-articulaterobot as the assembly loading means, a stable loading is facilitated.

According to a sixth aspect of the invention, there is provided apackaging system comprising: a packaging object manufacturing portionfor manufacturing a packaging object; and a packaging portion forpackaging the packaging object manufactured by the packaging objectmanufacturing portion in a predetermined fashion, wherein the packagingobject manufactured by the packaging object manufacturing portion ispackaged by the packaging portion without being deposited between beingmanufactured and being packaged.

In the packaging system of the present aspect, the packaging objectmanufactured by the packaging object manufacturing portion is suppliedto the packaging portion immediately without being deposited betweenbeing manufactured and being packaged, in other words, processing frommanufacturing of the packaging object in the packaging objectmanufacturing portion to packaging of the packaging object by thepackaging portion is executed as a sequential process.

Therefore, because no accumulating portion is necessary between thepackaging object manufacturing portion and the packaging portion unlikea conventional plastic case packed product packaging unit, there is noroom of producing any stock in the process. Thus, a period fromreception of an order for the packaging object to shipment to a customercan be reduced largely. Further, because a time in which the packagingobject remains in the process can be reduced, the efficiency of theentire packaging system is improved largely.

Additionally, because the packaging object manufactured by the packagingobject manufacturing portion is supplied to the packaging portionimmediately without being deposited between being manufactured and beingpackaged, a packaging object manufactured by the packaging objectmanufacturing portion first is supplied and packaged earlier than apackaging object manufactured later, so that so-called “first-infirst-out” can be achieved completely.

Therefore, because tracking can be carried out easily if any defect isfound out in inspection process after packaging at the packagingportion, the cause for that defect can be grasped easily.

The packaging object mentioned under the present invention includescommodity in which one or two products are accommodated in a small boxpackage such as a film cartridge, various kinds of canned beverages,copier toner container, as well as the aforementioned plastic casepacked product.

As for the style of packaging the packaging objects by the packagingportion, for example, one or multiple packaging objects are loaded insuch a small box as the sack carton so as to form a small box packageand then, the small box assembly is formed based on a predeterminedpattern and packed into a corrugated board box.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view showing the structure of anexample of a cartoner having the carton supplying unit according to aFirst Embodiment.

FIG. 2 is a schematic plan view of the cartoner shown in FIG. 1.

FIG. 3 is a plan view showing the detail of a carton opening formingportion included by the cartoner shown in FIG. 1.

FIGS. 4A and 4B are plan views showing a condition in which an openingis formed in the sack carton by the carton opening forming portion shownin FIG. 3.

FIG. 5 is a front view showing a condition in which the plastic casepacked product is loaded into the sack carton in the plastic case packedproduct loading portion included by the cartoner shown in FIG. 1.

FIG. 6 is a plan view showing the detail of the structure of an upperlid constructing portion included by the cartoner shown in FIG. 1.

FIG. 7 is a side view of the upper lid constructing portion shown inFIG. 6.

FIG. 8 is a front view of the upper lid constructing portion shown inFIG. 6.

FIG. 9 is a plan view showing the detail of the structure of a lower lidconstructing portion included by the cartoner shown in FIG. 1.

FIG. 10 is a side view of the lower lid constructing portion shown inFIG. 9.

FIG. 11 is a plan view showing the structure of a carton dischargingportion included by the cartoner shown in FIG. 1.

FIG. 12 is a plan view showing an operation of the carton dischargingportion shown in FIG. 11.

FIG. 13 is a plan view showing an operation of the carton dischargingportion shown in FIG. 11.

FIG. 14A is a perspective view showing an example of a cartonmanufactured by the cartoner shown in FIG. 1.

FIG. 14B is a perspective view showing conditions in which flap portionson both ends are constructed to form the upper and lower lids and inwhich the flap portions are opened in the sack carton for forming thecarton shown in FIG. 14A.

FIG. 15A is a perspective view showing another example of a cartonmanufactured by the cartoner shown in FIG. 1.

FIG. 15B is a perspective view showing still another example of a cartonmanufactured by the cartoner shown in FIG. 1.

FIG. 15C is a perspective view showing still another example of a cartonmanufactured by the cartoner shown in FIG. 1.

FIG. 16 is a flow chart showing a flow of the sack carton in thecartoner shown in FIG. 1.

FIG. 17 is a front view showing the structure of a carton supplyingchute in the carton supplying unit included by the cartoner shown inFIG. 1.

FIG. 18 is a plan view showing the structure of the carton supplyingchute shown in FIG. 17 when seen from above.

FIG. 19 is a front view of the carton supplying chute shown in FIG. 17when seen from a carton pickup port.

FIG. 20A is an enlarged side view showing the detail of the structure ofan upper pawl on a side provided with a load sensor and the surroundingof the upper pawl, of a pair of the upper pawls included by the cartonsupplying chute shown in FIG. 17.

FIG. 20B is a plan view of the upper pawl shown in FIG. 20A and itssurrounding.

FIG. 20C is a front view of the upper pawl shown in FIG. 20A and itssurrounding.

FIG. 21 is an enlarged view showing the detail of the structure of theother upper pawl and its surrounding.

FIG. 22A is an enlarged front view showing the detail of the structureof a lower pawl on a side provided with a load sensor and thesurrounding of the upper pawl, of a pair of the lower pawls included bythe carton supplying chute shown in FIG. 17.

FIG. 22B is an enlarged side view showing the detail of the structure ofa lower pawl on a side provided with a load sensor and the surroundingof the upper pawl, of a pair of the lower pawls included by the cartonsupplying chute shown in FIG. 17.

FIG. 23A is a plan view showing an example of a position in which theside pawl is provided of the carton supplying chute shown in FIG. 17.

FIG. 23B is a front view of the carton supplying chute having the sidepawls provided at a position shown in FIG. 23A.

FIG. 24 is an end face view showing a condition in which the positionsof the upper guide plate and horizontal guide are changed depending onthe size and configuration of the sack carton to be accommodated in thecarton supplying chute shown in FIG. 17.

FIG. 25 is a block diagram showing the structure of transportingvelocity control system for controlling the transporting velocities of amain belt conveyor and an auxiliary belt conveyor based on a signal froma load sensor in the carton supplying chute shown in FIG. 17.

FIG. 26 is a flow chart showing a sequence for controlling thetransporting velocities of the main belt conveyor and auxiliary beltconveyor based on a signal from the load sensor in a sequencer providedwith the transporting velocity control system shown in FIG. 25.

FIG. 27 is a block diagram showing a schematic structure of anotherexample of the carton supplying chute.

FIG. 28 is a block diagram showing a schematic structure of stillanother example of the carton supplying chute.

FIG. 29 is a structure diagram showing an entire structure of the cartonsupplying portion in the carton supplying unit included by the cartonershown in FIG. 1.

FIG. 30 is an enlarged plan view showing the detail of the structure ofa suction head included by the carton supplying portion shown in FIG.29.

FIG. 31 is an enlarged view of the suction head shown in FIG. 30 seenfrom a side provided with the suction cup.

FIG. 32 is a sectional view of the suction head shown in FIG. 30 takenalong the line A-A in FIG. 30.

FIG. 33 is a sectional view of the suction head shown in FIG. 30 takenalong the line B-B in FIG. 30.

FIG. 34 is a side view showing a condition in which the suction headshown in FIG. 30 is rotated around a rotation axis.

FIG. 35 is a schematic diagram showing a positional relation between asuction cup receiving drive unit and a suction head when the suctionhead included by the carton loading unit shown in FIG. 29 is located ata carton receiving position opposing a suction pickup port of thesuction supplying shoot.

FIG. 36 is a schematic diagram showing a positional relation between thesuction cup mounting drive unit and suction head when the suction headis located at the carton mounting position opposing an opening formingportion in the cartoner shown in FIG. 1.

FIGS. 37A through 37D are flow charts showing an operation of thesuction cup and sack carton in the vicinity of a carton pickup port whenthe carton is received.

FIG. 38 is a schematic plan view showing a positional relation among aprojecting portion provided in a guide plate of the carton receivingportion, an inside flap of the sack carton and an outside flap thereofwhen the carton receiving portion included by the suction headapproaches the sack carton located at the carton pickup port.

FIGS. 39A through 39C are flow charts showing a positional relationamong the carton receiving portion, the suction cup and the projectingportion in a period in which the carton receiving portion approaches thecarton pickup port, sucks the sack carton at the carton pickup port anddeparts from the carton pickup port.

FIG. 40 is an enlarged view showing an action of the suction cup and anaction of the sack carton accompanying it when the carton receivingportion departs from the carton pickup port.

FIG. 41 is a perspective view showing a schematic structure of anexample of the cartoner including the carton supplying unit according toa Second Embodiment.

FIG. 42 is a schematic plan view of the cartoner shown in FIG. 41.

FIG. 43 is a plan view showing the detail of the carton supplying shootand carton supplying portion included by the cartoner shown in FIG. 41.

FIG. 44 is a block diagram showing an entire constitution of anadhesive-injection inspection system according to a third embodiment.

FIG. 45A is a plan view showing a structure of a hot meltadhesive-injecting gun of the adhesive-injection inspection system shownin FIG. 44.

FIG. 45B is a front view of the hot melt adhesive-injecting gun shown inFIG. 45A.

FIG. 46A is a plan view showing a structure of a hot meltadhesive-injecting gun of the adhesive-injection inspection system shownin FIG. 44.

FIG. 46B is a front view of the hot melt adhesive-injecting gun of theadhesive-injection inspection system shown in FIG. 46A.

FIG. 47 is a block diagram showing a flow of signals in a CPU of theadhesive-injection inspection system shown in FIG. 44 and a schemedeterminating whether hot melt adhesive is normally injected at theabove-mentioned hot melt adhesive-injecting gun.

FIGS. 48A and 48B are graphs showing a relation of intensities ofsignals input into the above-mentioned CPU, on which basis the CPUdeterminates whether the intensity of the light received by an opticalfiber sensor is normal before injecting hot melt adhesive.

FIGS. 49A and 49B are graphs showing a relation of intensities ofsignals input into the CPU, on which basis the CPU determinates whetherthe intensity of the light received by an optical fiber sensor is normalwhen injection of hot melt adhesive is initiated.

FIG. 50A is a graph showing a relation of intensities of signals inputinto the CPU, on which basis the CPU determinates that the hot-meltadhesive is injected in a normal quality.

FIG. 50B is a graph showing a relation of intensities of signals inputinto the CPU, on which basis the CPU determinates that the hot-meltadhesive is injected in an abnormally small quality.

FIG. 51 is a graph showing a relation of intensities of signals inputinto the CPU, on which basis the CPU determinates that the hot meltadhesive is firstly injected in a normal quantity and later theinjection quantity is lowered to an abnormally small quantity.

FIG. 52 is a graph showing a relation of intensities of signals inputinto the CPU, on which basis the CPU determinates that cobwebbing wouldnot take place after stopping injection of the hot melt adhesive glue.

FIG. 53 is a graph showing a relation of intensities of signals inputinto the CPU, on which basis the CPU determinates that cobwebbing wouldtake place after stopping injection of the hot melt adhesive glue.

FIG. 54 is a plan view showing an entire constitution of a packagingsystem having a plastic case-packed product supplying apparatus relatingto a fourth embodiment.

FIG. 55 is a front view showing an entire construction of a plasticcase-packed product supplying apparatus shown in FIG. 54.

FIGS. 56A and 56B are expanded views showing a construction close to afirst horizontal conveyer carrying plastic case-packed product out of awinding machine, a vertical conveyer, and an inclined chute of a firstplastic case-packed product supplying line of the plastic case-packedproduct supplying apparatus shown in FIG. 55.

FIG. 57 is an expanded side view showing a relative location of the topportion of the vertical conveyer, plastic case-packed product-turningdevice, and the second horizontal conveyer of the first plasticcase-packed product supplying line.

FIG. 58 is an expanded top view of the top portion of the verticalconveyer and the plastic case-packed product-turning device.

FIGS. 59 and 60 are expanded views showing a mechanism of a portion ofthe winding machine incorporated in the packaging system shown in FIG.54, at which produced plastic case-packed products are carried out tothe first plastic case-packed product supplying line.

FIG. 61 is a plan view showing an entire construction of a plasticcase-packed product arraying portion incorporated into the plasticcase-packed product supplying apparatus shown in FIG. 55.

FIG. 62 is an expanded view showing the operation of the first pusherincorporated in the plastic case-packed product arraying portion shownin FIG. 61.

FIG. 63 is a side view showing a constitution of a lift-up conveyer anda plastic case-packed product arranging portion in the second plasticcase-packed product supplying line incorporated into the plasticcase-packed product supplying apparatus shown in FIG. 55.

FIG. 64 is a front view showing a detailed constitution of the plasticcase-packed product arranging portion incorporated in the second plasticcase-packed product supplying line.

FIG. 65 is an expanded perspective view showing a detailed constitutionof the lift-up conveyer incorporated in the second plastic case-packedproduct supplying line.

FIG. 66 is an expanded sectional view showing a detailed structure ofthe portion from the lift-up conveyer to the plastic case packed productarranging portion incorporated in the second plastic case-packed productsupplying line.

FIGS. 67A and 67B are partial expanded sectional views of the plasticcase packed product arranging portion.

FIG. 68 is an expanded view of the plastic case packed product arrangingportion carrying arranged plastic case-packed products out of theportion.

FIG. 69 is an expanded perspective view showing a constitution close toan arrangement transporting conveyer of the plastic case packed productarranging portion.

FIG. 70 is a front view showing an entire constitution of a plasticcase-packed product-introducing portion of the plastic case-packedproduct supplying apparatus shown in FIG. 55.

FIGS. 71A and 71B are expanded views showing a detailed constitution ofa conveyance jamming-detecting portion incorporated in the plasticcase-packed product-introducing portion shown in FIG. 70.

FIG. 71C is a perspective view of a portion of FIG. 71B.

FIG. 72 is a partial side view of a direction-detecting portion includedin the plastic case-packed product-introducing portion shown in FIG. 70.

FIG. 73 is a partial plan view showing the top view of thedirection-detecting portion shown in FIG. 72.

FIG. 74 is an expanded view showing a detailed constitution of thedirection-detecting portion shown in FIG. 72.

FIG. 75 is an expanded view showing a backside view ofdirection-detecting dogs (direction-detecting probes) incorporated inthe direction-detecting portion shown in FIG. 72.

FIGS. 76A through 76D are block diagrams showing operation of thedirection-detecting dogs showing in FIG. 75.

FIG. 77 is an expanded front view showing a constitution of a plasticcase-packed product-delivering portion and a plastic case-packedproduct-accepting portion incorporated in the plastic case-packedproduct introducing portion shown in FIG. 70.

FIG. 78 is an expanded plan view showing a top view of the plasticcase-packed product delivering and accepting portions shown in FIG. 77.

FIG. 79A is a plan view and FIG. 79B is a front view, both of which showthe plastic case-packed product-accepting portion having an open-closeguide closed.

FIG. 80A is a plane vie and FIG. 80B is a front view, both of which showthe plastic case-packed product-accepting portion having an open-closeguide opening.

FIGS. 81A and 81B are a flow chart showing operation delivering plasticcase-packed product from the plastic case-packed product-deliveringportion to the plastic case-packed product-accepting portion.

FIGS. 82A and 82B are flow charts showing operation delivering plasticcase-packed product from the plastic case-packed product-deliveringportion to the plastic case-packed product-accepting portion.

FIG. 83 is a plan view showing an entire constitution of a packagingsystem of a fifth embodiment.

FIG. 84 is a block diagram showing a constitution of a winding machineincorporated in the packaging system shown in FIG. 83.

FIG. 85 is a schematic diagram showing the constitution of the windingmachine incorporated in the packaging system shown in FIG. 83.

FIG. 86 is a brief perspective view showing a constitution of a cartonerincorporated in the packaging system shown in FIG. 83.

FIG. 87 is a side view showing a constitution of a carton-boxingapparatus incorporated in the packaging system shown in FIG. 83.

FIG. 88 is a partial side view showing a carton assembling apparatusincorporated in the carton-boxing apparatus shown in FIG. 87.

FIG. 89 is a plan view showing an entire constitution of the cartonassembling apparatus and a partial constitution of a shrink packagingunit incorporated in the packaging system shown in FIG. 83.

FIG. 90A is a partial plan view and FIG. 90B is a partial side view,both of which show a first conveyer incorporated in the cartonassembling apparatus shown in FIGS. 88 and 89.

FIG. 91 shows a sectional view of the first conveyer shown in FIG. 90Aand 90B sectioned at a lane perpendicular to the conveyance directionthereof.

FIG. 92 is a plan view showing an entire constitution of the secondconveyer incorporated in the carton-assembling apparatus shown in FIGS.88 and 89.

FIG. 93 is a side view of the second conveyer.

FIG. 94 shows a sectional view of the second conveyer from thedownstream with respect to the conveyance direction.

FIG. 95 is a plan view showing a detailed constitution of a downstreamend portion of the second conveyer.

FIG. 96 is an expanded view showing a relative relation of the locationsof a group of cartons (five cartons) conveyed on the second conveyer anda sixth carton that is conveyed following to the previous group ofcartons (previous five cartons).

FIGS. 97A and 97B are a plan view and a side view, respectively, whichshow a third conveyer incorporated in the carton-assembling apparatusshown in FIGS. 88 and 89.

FIGS. 98A and 98B are a plan view of a fifth conveyer incorporated inthe carton-assembling apparatus shown in FIGS. 88 and 89, and a sideview of the fifth conveyer, respectively.

FIG. 99 is a perspective view showing a first robot incorporated in thecarton-assembling apparatus shown in FIGS. 88 and 89.

FIG. 100 is a schematic diagram showing a relation between a carton andX, Y, and Z-axis.

FIG. 101 is a perspective view showing a second robot incorporated inthe carton-assembling apparatus shown in FIGS. 88 and 89.

FIG. 102 is a perspective view showing a third robot incorporated in thecarton-assembling apparatus shown in FIGS. 88 and 89.

FIG. 103 is a perspective view showing a detailed constitution of achucking unit incorporated in the third robot shown in FIG. 102.

FIG. 104 is a plan view of a shrink packaging unit incorporated in thecarton-boxing apparatus shown in FIG. 87.

FIG. 105 is a perspective view showing a detailed constitution of anintroducing conveyer, a shrink film-covering portion, a heat sealingunit, shrinking unit, amount-supplying unit and a shrinkingfilm-supplying unit incorporated in the a shrink packaging unit shown inFIG. 104.

FIG. 106 is a perspective view showing a detailed constitution of aheight-arranging portion incorporated in the shrink-packaging unit shownin FIG. 104.

FIG. 107 is a perspective view showing a detailed constitution of anend-arranging transporting portion incorporated in the shrink-packagingunit shown in FIG. 104.

FIG. 108 is a side view showing a constitution of a corrugated boardcasing unit incorporated in the carton boxing apparatus shown in FIG.87.

FIG. 109 is a perspective view showing a detailed constitution of aproduct-loading robot incorporated in the corrugated board casing unitshown in FIG. 108.

FIG. 110 is a perspective view showing a detailed constitution of a handportion of the product-loading robot shown in FIG. 109.

FIG. 111 is a perspective view showing a detailed constitution close tofinger-like members of the hand portion shown in FIG. 110.

FIG. 112 is a flow chart showing a series of operation of theproduct-loading robot shown in FIG. 109 loading a carton assembly or ashrink-wrapped package.

FIGS. 113A and 113B are schematic diagrams showing operation of thefinger-like members at the time when grasping a carton assembly or ashrink-wrapped package.

FIGS. 114A and 114B are schematic diagrams showing operation of thefinger-like members at the time when loading the carton assembly or theshrink-wrapped package into a corrugated board box.

FIGS. 115 and 116 are perspective views showing a detailed constitutionof an empty corrugated board box-transporting portion incorporated inthe corrugated board-casing unit shown in FIG. 108.

FIG. 117 is a perspective view showing a detailed constitution of acorrugated board box-positioning portion incorporated in the corrugatedboard-casing unit shown in FIG. 108.

FIGS. 118 and 119 are perspective views showing a detailed constitutionof a product-loaded corrugated board box-transporting portionincorporated in the corrugated board-casing unit shown in FIG. 108.

FIG. 120 is a block diagram showing a constitution of a control computerincorporated in the packaging system shown in FIG. 83.

FIG. 121 is a perspective view showing an example of a corrugated boardbox with a partition that can be employed in the packaging system shownin FIG. 83.

FIG. 122 is a plan view showing a view of the corrugated board box witha partition shown in FIG. 121 from an opening from which a cartonassembly or a shrink-wrapped package is loaded.

FIG. 123 is a development of the corrugated board box with a partitionshown in FIG. 121.

FIG. 124 is a perspective view showing another example of a corrugatedboard box with a partition that can be employed in the packaging systemshown in FIG. 83.

FIG. 125 is a development of the corrugated board box with a partitionshown in FIG. 124.

FIGS. 126A through 126H are flow charts showing a process of loadingshrink-wrapped packages or carton assemblies into a corrugated board boxwith a partition shown in FIG. 121 to 125.

FIG. 127 is a flow chart showing a flow of materials in the packagingsystem shown in FIG. 83.

FIG. 128 is a perspective view showing an example of a carton having noheader that is included in a carton that can be into a corrugated boardbox with a partition in the packaging system shown in FIG. 83.

FIG. 129 is a perspective view showing another example of a cartonhaving no header.

FIG. 130 is a perspective view showing a different example of a cartonhaving no header.

FIG. 131 is a perspective view showing a different example of a cartonhaving no header.

FIG. 132 is a perspective view showing an example of a carton having aheader at an end surface of its main body that is included in a cartonthat can be loaded into a corrugated board box with a partition in thepackaging system shown in FIG. 83.

FIG. 133 is a perspective view showing another example of a cartonhaving a header at its end surface.

FIG. 134 is a perspective view showing a different example of a cartonhaving a header at its end surface.

FIG. 135 is a perspective view showing a different example of a cartonhaving a header at its end surface.

FIG. 136 is a perspective view showing an example of a carton having aheader wider than its main body at an end surface thereof that isincluded in a carton that can be loaded into a corrugated board box witha partition in the packaging system shown in FIG. 83.

FIG. 137 is a perspective view showing another example of a cartonhaving a header wider than its box body at its end surface.

FIG. 138 is a perspective view showing a different example of a cartonhaving a header at a side edge of its main body.

FIG. 139 is a perspective view showing a different example of a cartonhaving a header at a side edge of its main body.

FIGS. 140A to 140G are flow charts showing a scheme of packing a cartonshown in FIG. 136 accommodating 1 plastic case-packed products andhaving a header wider than its main body into a shrink-wrapped packageand loading the shrink-wrapped package into a corrugated board box.

FIGS. 141A to 141E are flow charts showing a scheme of packing into ashrink-wrapped package and loading the shrink-wrapped package into acorrugated board box for a carton shown in FIG. 133 accommodating 3plastic case-packed products and having a header of the same width asthat of its main body.

FIGS. 142A to 142G are flow charts showing a scheme of packing into acarton assembly of ten cartons and loading the carton assembly into acorrugated board box in the packaging system relating to the fifthembodiment for a carton shown in FIG. 132 accommodating 2 plasticcase-packed products and having a header of the same width of that ofits main body.

FIGS. 143A to 143H are flow charts showing a scheme of packing into ashrink wrapped package and loading the shrink wrapped package into acorrugated board box in the packaging system of the fifth embodiment fora carton shown in FIG. 138 accommodating 3 plastic case-packed productsand having a header at the side edge of its main body.

DESCRIPTION OF THE PREFERRED EMBODIMENTS A First Embodiment

A carton supplying unit, which is an example of the box body supplyingapparatus of the present invention, and a cartoner which is an exampleof the boxing apparatus of the invention and has the carton supplyingunit will be described as follows.

The cartoner refers to a boxing apparatus for packaging a film cartridgeaccommodated in a moisture-proof case in a sack carton and the cartonsupplying unit is a box body supplying apparatus for supplying the sackcarton to the cartoner.

1-1 Cartoner

As shown in FIGS. 1 and 2, a cartoner 400 refers to a cartoner in whicha cylindrical plastic case packed product is packaged inside the sackcarton C which is a box body having flap portions forming an openingportion and a lid portion for covering the opening portion on both ends.The plastic case packed product refers to a cylindrical plastic case foraccommodating a film cartridge.

As shown in FIGS. 1 and 2, the cartoner 400 comprises a carton supplyingunit 2, a rotation table 4 which holds the sack carton C supplied fromthe carton supplying unit 2 on its outer peripheral portion and rotatesintermittently clockwise as indicated by an arrow a, a carton openingforming portion 6 which is provided at a position opposing the cartonsupplying unit 2 in the vicinity of the rotation table 4 and after asack carton C supplied from the carton supplying unit 2 is constructedfrom its folding condition and mounted on the outer peripheral portionof the rotation table 4 with an opening portion on the side in which aheader C2 is provided facing downward, constructs a part of a flapportion on its bottom side and partially closes the bottom opening, aplastic case-packed product packing portion 8, which is providedadjacent to the downstream side (hereinafter referred to as “downstreamside”) along the rotation direction a relative to the carton openingforming portion 6 for loading a predetermined quantity of the plasticcase packed products, for example, four products accommodating acartridge in a lid provided cylindrical plastic case from an upperopening portion with the bottom opening of the sack carton C closedpartially, an upper lid constructing portion 10 which is providedadjacent to the downstream side of the plastic case-packed productpacking portion 8 for forming an upper lid by constructing a remainderof the flap portion on the bottom side, a bottom lid constructingportion 12 which is provided adjacent to the downstream side of theupper lid constructing portion 10 for forming a bottom lid for closingthe upper opening portion of the sack carton C by constructing a flapportion or the upper side and a carton discharging portion 14 which isprovided adjacent to the downstream side of the bottom lid constructingportion 12 for discharging the sack carton C in which the plastic casepacked products are packaged outside.

A hot melt adhesive injecting gun 20 is disposed between the upper lidconstructing portion 10 and the bottom lid constructing portion 12 toapply hot melt adhesive to a flap portion C12 constituting an upper lidC8 of the sack carton C. On the other hand, a hot melt adhesiveinjecting gun 22 is disposed between a first pusher 12C and a secondpusher 12D located downstream thereto in the bottom lid constructingportion 12. The hot melt adhesive injecting gun 22 applies hot-metadhesive to an inside surface of an outside flap C22.

The rotation table 4, the carton opening forming portion 6, the aplastic case-packed product packing portion 8, the upper lidconstructing portion 10, the bottom lid constructing portion 12 and thecarton discharging portion 14 are mounted at a specific location on abase (not shown).

As shown in FIGS. 14A and 14B, the sack carton C is a square rod likebox body in which a header C2, which is a tab-like member to be hung bya hook, is formed on an end portion and four plastic case packedproducts are accommodated at right angle relative to the longitudinaldirection of the sack carton C.

As shown in FIG. 14B, opening portions C4, C6, the flap portion C12which forms the upper lid C8 for covering the opening portion C4 and aflap portion C14 which forms a bottom lid C10 for covering the openingportion C6 are formed at each end portion.

The flap portion C12 has a pair of inner flaps C16 which form an insideportion of the upper lid C8 and a folding portion and further containsan outside flap C18 which forms an outside portion of the upper lid C8.The outside flap C18 is provided at a position opposing a header C2.

Likewise, the flap portion C14 has a pair of inside flaps C20 which formthe inside portion of the bottom lid C10 and a pair of the outside flapsC22 which form an outside portion of the bottom lid C10.

As the sack carton C, in addition to the type shown in FIG. 14, a sackcarton which accommodates four pieces of the plastic case packedproducts at right angle relative to the longitudinal direction and hasno header as shown in FIG. 15A is also available and a sack carton whichhas a header C2 at the upper end and accommodates two pieces of theplastic case packed products at right angles relative to thelongitudinal direction as shown in FIG. 15B and a sack carton which isprovided with the header C2 adjacent to one of the folding portionsforming a side edge and accommodates four pieces of the plastic casepacked products at right angle relative to the longitudinal direction asshown in FIG. 15C also can be used.

As shown in FIG. 1, the rotation table 4 has substantially circularindex tables 4A and 4B disposed coaxially in a vertical directions. Theindex table 4A located at the bottom side and the index table 4B locatedat the upper side relatively rotate intermittently along the rotationdirection a around a center point while maintaining the upper endportion and the lower end portion of the sack carton C such that theheader C2 is located outside on each outer peripheral portion.Consequently, the sack carton C is transported in the order of thecarton opening forming portion 6, the plastic case-packed productpacking portion 8, an upper lid constructing portion 10A, a bottom lidconstructing portion 12 and a carton discharging portion 14.

The index tables 4A, 4B are constructed to be capable of approaching orleaving each other in the vertical direction so as to hold upper end andlower end of the carton when a carton of a different size istransported.

The carton opening forming portion 6 is, as shown in FIGS. 1 and 2,comprises an opening forming device 6A for constructing a cartonsupplied from the carton supplying unit 2 into a square rod like formwhich allows the plastic case packed products to be loaded by forming anopening, a flap folding arm 6B for folding an inside flap C16 located onthe upstream side (hereinafter referred to as “upper stream side”)relative to the rotation direction a of a pair of the inside flaps C16included by the flap portion C12 in a direction covering the openingportion C4, and a flap folding plate 6C which is a circular plate-likemember provided adjacent to the downstream side of the flap folding arm6B and along the outer periphery of the index table 4A.

As shown in FIGS. 3, 4A and 4B, the opening-forming device 6Aincorporates an opening-forming guide member 6A2 fixed so as to facingthe index table 4A and a opening-forming pusher member 6A4 formed so asto move along the opening-forming guide member 6A2 to approach or partfrom the index table 4A.

The opening-forming guide member 6A2 has a guide surface 6A6 shaped in ataper at one end and is located at a location wherein a corner portionof a sack carton C supplied by the carton supplying unit 2 and shown intwo-dot chain line in FIG. 4A rides on the guide surface 6A6 so that theguide surface 6A6 faces the index table 4A. On the other end of theopening-forming guide member 6A2, a slide guide 6A10 guiding theopening-forming pusher member 6A4 is disposed.

The opening-forming pusher member 6A4 is provided in a tangentialdirection to the index table 4A so as to push the sack carton C at itstip portion. At its root portion, a slider 6A8 sliding on the slideguide 6A10 is provided.

When a folded sack carton C is approaching to a carton-setting portion42 of the index table 4 by the carton supplying unit 2, as shown intwo-dot chain line in FIG. 4A, a corner portion of the sack carton C ispressed onto the guide surface 6A6 and the sack carton C is partiallyopened.

Them as shown in bold line in FIG. 4A, the opening-forming pusher member6A4 moves to a location facing the carton-setting portion 42 to push thecarton C so as to folded in an opposite direction. Thus, the carton Clooses its shape-restoring force and is opened into a square box. Afterpushing the carton C, the opening-forming pusher member 6A4 returns to alocation wherein not interrupting the setting of the sack carton C intothe carton-setting portion 42. Thus, the sack carton is prevented frompopping out of the carton-setting portion by its shape-restoring force.

As shown in FIGS. 1 to 3, the flap-folding arm 6B is protruded frominside of the index table 4A to outside, has a front-end portion 6B2formed in a hook shape and directed to the downstream, and is mountedrotatably on the base (not shown) by an axis 6B8. The opposite end ofthe flap folding arm 6B is connected to a piston 6B12 of an aircylinder. Thus, the flap-folding arm 6B rotates around the axis 6B8 by areciprocal action of the piston 6B12.

By retracting the piston 6B12, the flap folding arm 6B rotates in adirection that the front-end portion 6B2 approaches to an inner flap C16located in the upstream side, and thus, the inner flap C16 is foldedtoward the downstream side so as to cover the opening portion C4.

The flap folding plate 6C is extended from the carton opening formingportion 6 to the upper lid constructing portion 10. When the rotationtable 4 rotates in the direction of an arrow a, the inside flap C16 inthe downstream side is folded to the upstream side so as to overlap theinside flap C16 in the upstream side. When the inside flap C16 on thedownstream side is folded, the inside flap C16 is held from downward notso as to open until the sack carton C reaches the upper lid constructingportion 10 from the carton opening forming portion 6 through the plasticcase-packed product packing portion 8.

As shown in FIGS. 1, 2 and 5, the plastic case-packed product packingportion 8 comprises a plastic case-packed product pressing device 8Awhich is located above the index table 4B and brings with a pressure apredetermined quantity, for example, four plastic case packed productsinto the inside of the sack carton C and a plastic case supplying unit8B for supplying the predetermined quantity of the plastic case packedproducts to the plastic case pressing unit 8A. Because the inside flapC16 located downward is held from down by the flap folding plate 6C whenthe plastic case packed products are loaded into the plastic casepressing unit 8A, the loaded plastic case packed products never dropfrom the opening portion C4 of the sack carton C.

As shown in FIG. 5, the plastic case pressing unit 8A has a plastic casesupplying shoot 828F that is provided on the index table in a verticaldirection and has a C-shaped section opened toward the plastic casesupplying device, an open-close accepting guide 828A surrounding theplastic case supplying shoot 828F, a pusher 8A2 going upward anddownward in the plastic case supplying shoot 828F, and a pair ofopen-close guides 828G located at the bottom of the open-close acceptingguide 828A. The open-close guides 828G are urged by a helical spring(not shown) upwardly, i.e., in a direction so that the open-close guides828G close. The open-close guides 828G also form a bottom of the plasticcase supplying shoot 828F when they close. When they open, the tip ofthe open-close guides 828G touches the inside wall of the sack carton Cand functions as a guide guiding plastic case packed products falling inthe plastic case supplying shoot 828F into the sack carton C.Additionally, the open-close guides 828G are preferably formed so thatthe tip portions thereof are inserted in the sack carton C in a lengthof 2 mm or more when the they open since the plastic case packedproducts P are introduced in the sack carton without being caught by thetip portions thereof.

When providing the plastic case packed products P from the plastic casesupplying unit 8B to the plastic case pressing device, the open-closeaccepting guide 828A opens and the plastic case packed products P aredelivered to the plastic case supplying shoot 828F in an specificnumber. At that time, the open-close guide 828G is closed.

After the plastic case packed products P are supplied to the plasticcase supplying chute 828F, the open-close accepting guide 828A closesand the pusher 8A2 descends to press the plastic case packed product tothe downward. Thus, the open-close guides open and the plastic casepacked products in the plastic case supplying chute 828F are loaded inthe sack carton C.

The upper lid constructing portion 10 comprises an outside flap foldingmember 10A which is located at a standby position inside of the flapfolding plate 6C or a flap folding position outside of the flap foldingplate 6C and folds the outside flap C18 of the flap portion C12 towardthe header C2 when it moves from the standby position outward toward theflap folding position, a header supporting plate 10B which supports theheader C2 from outside not so as to be folded outward when the outsideflap C18 is folded by the outside flap folding member 10A, an upper lidfolding unit 10M which forms the upper lid C8 by folding upward theoutside flap C18 bent by the outside flap folding member 10A and theheader supporting plate 10B.

As shown in FIGS. 6 and 7, the outside flap folding member 10A and theheader supporting plate 10B are fixed to sliders 10A2 and 10B2,respectively. The sliders 10A2 and 10B2 slides on the guide 10C disposedin a radial direction of the index table 4A.

Below the guide 10C, a swing arm 10E is mounted on the base by an axis10F. At one end of the swing arm 10E, a pin 10E2 is disposed and at theother end thereof, a pin 10E4 is disposed.

An engaging portion 10D having an L-shape is provided on the slider 10A2and a helical spring 10G is disposed between the slider 10A2 and theguide 10C and thus, the helical spring 10G urges the slider 10A2 and theoutside flap folding member 10A so that the engaging portion 10D touchesthe pin 10E2.

The slider 10B2 incorporates an engaging portion 10H having an L-shapeand a helical spring 10I is provided between the slider 10B2 and theguide 10C. The helical spring 10I urges the slider 10B2 and the headersupporting plate 10B so that the engaging portion 10H touches the pin10E4.

A pocket 10E6 in which the pin 10E4 is retracted is provided on theswing arm 10E at a portion below the pin 10E4. Below the pocked 10E6, anair cylinder 10E8 popping and retracting the pin 10E4 is fixed. The pin10E4 is fixed on the piston 10E10 of the air cylinder 10E8 so as to popout of the pocket 10E6 when the piston 10E10 is expanded and to beretracted inside of the pocket 10E6 when the piston 10E10 is contracted.

When the sack carton has a pair of outside flap C18 instead of theheader C2 located adjacent to the upper lid C8, at the swing arm 10E,the piston 10E10 is expanded and the pin 10E4 pops over the swing arm10E. Thus, when the swing arm 10E rotates contra-clockwisely in FIG. 6around the axis 10F, the outside flap folding member 10A and the headersupporting plate 10B approach each other as shown in FIG. 8 and foldentirely the outside flap C18 upward as well as the outside flap foldingmember 10A and the template 10J co-operate to fold an folding portion(tip portion) of the outside flap C18.

On the other hand, when the sack carton C has a header C2 adjacent tothe upper lid C8, at the swing arm 10E, the piston 10E10 is contractedand the pin 10E4 is retracted into the pocket 10E6. Thus, the force ofrotation from the swing arm 10E is not transferred to the headersupporting plate 10B and therefore, the header supporting plate 10B isurged by the helical spring 10I to contact to the stopper 10K to standat a location A in FIG. 8. Thus, the header C2 is supported from theoutside by the header supporting plate 10B while the outside flap C18 isbeing folded.

As shown in FIG. 10, the upper lid folding unit 10M incorporates a pairof guide plates 10M4 having a cylindrical guild surface 10M2 guiding theoutside flap C18, a horizontal pusher 10M6 pushing the outside flap C18horizontally, and a vertical pusher pushing the outside flap C18 upward.

A guide 10M10 is fixed on the base and a slider 10M12 is fixed to thehorizontal pusher 10M6. By the slider 10M12 sliding on the guide 10M10,the horizontal pusher 10M6 approaches and parts from the guide plate10M4. Additionally, the horizontal pusher 10M6 is connected to thespline shaft 12A2 by a spline nut 10M14 and an arm 10M16. Thus, by thespline shaft 12A2 rotating, the horizontal pusher 10M6 movesreciprocally between a rest position shown in bold line and a foldingposition shown in two-dot chain line in FIG. 10.

By the horizontal pusher 10M6 moving from the rest position to thefolding position, the outside flap C18 of the sack carton C is guidedalong the guide surface 10M2 of the guide plate 10M4 to a foldingposition shown in two-dot chain line in FIG. 10.

Then, the vertical pusher 10M8 ascends from a rest position shown inbroken line to a folding position shown in two-dot chain line in FIG.10. Thus, the outside flap is pushed by the vertical pusher 10M8 to befolded completely in an angle of 90 degree to complete the upper lid C8.

The bottom lid constructing portion 12 is provided such that it adjoinsthe index table 4B above the upper lid folding unit 10M. The bottom lidconstructing portion 12 comprises a flap folding arm 12A which folds oneinside flap 20 of the bottom lid C10 toward the opening portion C6, aflap folding plate 12B which is a circular plate-like member adjacent tothe downstream side of the flap folding arm 12A and extended along theouter periphery of the index table 4B, a roller-like first pusher 12Cadjacent to the downstream side of the flap folding plate 12B and asecond pusher 12D adjacent to the downstream side of the first pusher12C.

The flap folding arm 12A is a plate-like member which is extended fromoutside to inside of the index table 4B while its front end is formed ina hook like shape. Then, this is formed rotatably around the rotationaxis provided on a root portion which is an end portion opposite to theside formed in the hook-like shape. When the flap folding arm 12Arotates toward downstream side, the hook-shaped end portion abuts on theinside flap C20 in the upstream so that it folds the inside flap C20toward the downstream so as to cover the opening portion C6.

When the rotation table 4 rotates in the direction of an arrow a, theflap folding plate 12B folds the inside flap C20 on the downstream sideof the sack carton C toward the upstream side so as to overlap theinside flap C20 on the upstream side. If the inside flap C20 on thedownstream side is folded, the pair of the inside flaps C20 are heldfrom upward not so as to open until the sack carton C reaches the firstpusher 12C.

The first pusher 12C is formed so as to be capable of advancing orretracting along the radius direction of the index table 4B. When itadvances toward the center of the index table 4B, one outside flap C22located outside of the pair of the outside flaps C22 is folded inward soas to overlap the inside flap C20.

The second pusher 12D is also formed so as to be capable of advancing orretracting along the radius direction of the index table 4B similarly tothe first pusher 12C. If it retracts toward the outer periphery of theindex table 4B, it folds and bond the outside flap C22 so as to overlapthe outside flap C22 thereby forming the bottom lid C10.

As shown in FIGS. 11 to 13, the carton discharging portion 14 comprisesa walking table 14A on which the sack carton C of which bottom lid C10is constructed at the bottom lid constructing portion 12, a pair ofpick-up forks 14B picking the sack carton C out of the carton settingportion 42 of the index tables 4A and 4B, a discharging fork 14Cdischarging the sack carton C picked out of the carton setting portion42 to an discharging conveyer 14D, and the discharging conveyerdischarging the sack carton C out of the cartoner 400.

The walking table 14A and the pick-up forks 14B walk in a synchronizedmanner between a sack carton accepting position shown in FIG. 11 and asack carton delivering position shown in FIGS. 12 and 13 by a slidermechanism 14E provided in a radial direction of the index tables 4A and4B.

The slider mechanism 14E comprises a linear guide 14G, a slider 14F withthe walking table 14A and the pick-up fork 14B fixed thereon and slidingon the linear guide 14G, a driving lever 14H driving the slider 14F, aslider 14I fixed to the upper pick-up fork 14B and a linear guide 14J onwhich the slider 14I slides.

On the other hand, the discharging fork 14C walks by a slider mechanism14K in a direction approaching the discharging conveyer 14D or in adirection parting therefrom.

The slider mechanism 14K has a linear guide extending in a directionparallel to the discharging conveyer 14D and a slider 14L with thedischarging fork 14C fixed thereon and sliding on the linear guide 14M.

Additionally, at the tip portion of the discharging fork 14C, claws 14A2and 14A4 are provided.

An operation of the carton discharging portion 14 is described in thebelow.

When the sack carton with its bottom lid C10 constructed at the bottomlid constructing portion 12 is moved to the carton discharging portion14 by the index tables 4A and 4B, the walking table 14A and the pick-upforks are at the sack carton accepting position shown in FIG. 11.

When the sack carton C is mounted on the walking table 14A, the walkingtable 14A and the pick-up forks 14B moves by the slider mechanism 14E tothe sack carton delivering position as shown in FIG. 12 and remove thesack carton from the carton setting portion 42 to the discharging fork14C. Thus, as shown in FIG. 12, the discharging fork 14C is at aposition parting from the discharging conveyer 14D.

Finally, as shown in FIG. 13, the discharging fork 14C moves toward thedischarging conveyer 14D by the slider mechanism 14K and discharge thesack carton C to the discharging conveyer 14D.

The sack carton C discharged on the discharging conveyer 14D isdischarged out of the cartoner 400 by the discharging conveyer 14D.

The entire operation of the cartoner 400 is described below. In themeantime, a flow of the carton and the plastic case packed products inthe cartoner 400 is shown in FIG. 16.

As shown in FIGS. 1 and 16, in the sack carton C supplied to thecartoner 400 by the carton supplying unit 2, an opening is formed at thecarton opening forming portion 6 and it is mounted on the rotation table4. Then, an inside flap C16 is folded by the flap folding arm 6B and theflap folding plate 6C so as to cover the opening portion C4.

The opening is formed in the carton opening forming portion 6 and afterthe opening portion C8 is covered, the sack carton C is transported tothe plastic case-packed product packing portion 8. Then, a predeterminedquantity of the plastic case packed products are loaded in the plasticcase packing portion C8.

After the predetermined quantity of the plastic case packed products areloaded in the plastic case packing portion C8, the sack carton C istransported to the upper lid constructing portion 10. There, the outsideflap C18 is folded and bonded to the inside flap thereby forming theupper lid C8.

In the sack carton C, at the same time when the upper lid C8 is formedby the upper lid constructing portion 10, the inside flap C20 is foldedat the bottom lid forming portion 12 so as to cover the opening portionC6. Then, the outside flap C22 is folded successively and bonded so asto form the bottom lid C10.

After the bottom lid C10 is formed, the sack carton C is transported tothe carton discharging portion 14 and discharged from the cartoner 400and sent to a post process.

1-2 Carton Supplying Unit

As shown in FIG. 17, the carton supplying unit 2 comprises a cartonsupplying chute 100 accommodating a number of the sack cartons C and acarton supplying portion 200 for bringing out the sack carton C from thecarton supplying chute 100 and supplying to the carton opening formingportion 6.

(A) Carton Supplying Chute

The carton supplying chute 100 corresponds to the box body accommodatingportion in the box body supplying unit of the invention. As shown inFIGS. 17 to 19, it comprises a carton supplying conveyor portion 102which includes a carton pickup port 104 corresponding to a box bodypickup port according to the invention provided at an end portion,accommodates the sack carton C and transports the sack carton C towardthe carton pickup port 104 and a base 180 for supporting the cartonsupplying conveyor portion 102 from the below.

A supplying chute front end portion 106 is formed in the vicinity of thecarton pickup port 104 of the carton supplying conveyor portion 102.

The carton supplying conveyor portion 102 comprises a main belt conveyor108 constituted of three belt conveyors arranged in parallel, a pair ofend plates 112 provided in parallel to the main belt conveyor 108 so asto sandwich the main belt conveyor 108 in the width direction and ahorizontal guide 110 disposed between the end plate 112 and the mainbelt conveyor 108 in parallel to the main belt conveyor 108. Thehorizontal guide 110 corresponds to the horizontal guide memberaccording to the invention. The carton supplying conveyor 102 is fixedon the base 180 at the end plate 112.

A drive roller 108A for supporting the main belt conveyor 108 and adriven roller 108B are pivoted by the end plate 112.

The horizontal guide 110 is comprised of a reference side guide member110A fixed to the carton supplying conveyor portion 102 and a movingside guide member 110B formed so as to be capable of approaching orleaving the reference side guide member 110A.

The horizontal guide 110 is provided with a width adjusting guide 114for guiding the main belt conveyor 108 along the width direction whenthe moving side guiding member 10B is moved relative to the referenceside guiding member 110A such that it is at right angle to the main beltconveyor 108 when it passes through the main belt conveyor 108. Twopieces of the width adjusting guides 114 are arranged along thelongitudinal direction of the main belt conveyor 108. An end of thewidth adjusting guide 114 is fixed on the reference side guide member110A while the other end is fixed to the moving side guide member 110B.A horizontal guide width adjusting motor 1116 for moving the moving sideguide member 110B is provided below the end plate 112.

As shown in FIGS. 17 to 19, the supplying shoot front end portion 106has a function for feeding the sack carton C transported near thesupplying shoot front end portion 106 by the main belt conveyor 108 tothe carton pickup port 104 and includes an auxiliary belt conveyor 118provided in parallel to the main belt conveyor 108.

Three auxiliary belt conveyors 118 are provided and two of them areprovided in the main conveyor 108 while the other one is providedbetween the main conveyor 108 and the reference side guide member 110A.The auxiliary belt conveyor 118 is wound around the drive roller 118Aand the driven roller 118B. The drive roller 118A has the same diameteras the drive roller 108A and is provided coaxially with the drive roller108A such that it is sandwiched by the drive roller 108A.

The drive roller 108A and the drive roller 118A are driven by the beltconveyor drive unit 108C fixed to the end plate 112.

The belt conveyor drive unit 108C is formed such that one of rotatingone of the drive roller 108A and the drive roller 118A, and rotating theboth is selectable. Such a belt conveyor drive unit 108C comprises amotor 108D, a first clutch 108E for transmitting a rotation of the motor108D to the drive roller 108A and a second clutch 108F for transmittinga rotation of the motor 108D to the drive roller 118A.

In the belt conveyor drive unit 108C, if the motor 108D is rotated withonly the first clutch 108E set to “in contact”, only the drive roller108A is rotated and then only the main belt conveyor 108 is driven. Ifthe motor 108D is rotated with only the second clutch 108F set to “incontact”, only the drive roller 118A is rotated and then only theauxiliary belt conveyor 118 is driven. Then, if both the first clutch108E and the second clutch 108F are set to “in contact”, the driverollers 108A and 118A are rotated at the same velocity, so that the mainbelt conveyor 108 and the auxiliary belt conveyor 118 are driven at thesame transfer velocity.

If other transmission gear is employed instead of the first clutch 108Eand the second clutch 108F, the main belt conveyor 108 and the auxiliarybelt conveyor 118 are driven at different transfer velocities.

As the belt conveyor drive unit 108C, a first motor for driving thedrive roller 108A and a second motor for driving the drive roller 118A,provided independently of the first motor may be provided.

Preferably, the auxiliary belt conveyor 118 is composed of materialhaving a low friction coefficient such as fluororesin in order toprotect the sack carton C from being damaged when it slips.

The actuator supporting base 124 is fixed on the end plate 112 by meansof four supporting columns 126 above the auxiliary belt conveyor 118 andan upper guide plate 146, which will be described later, is mounted onan actuator supporting base 124 through the upper guide plate mountingportion 122 such that it is capable of rising or falling and an upperguide plate 160, which will be described later, is mounted through theupper guide plate mounting portion 120 such that it is capable of risingor falling. Two supporting columns 126 are mounted on a supportingcolumn receiving plate 128 fixed on an upper edge of the end plate 112such that they are located outside the horizontal guide 110.

An pickup port guide plate 130 is provided on the side of the cartonpickup port 104 of the auxiliary belt conveyor 118 to prevent the sackcarton C transported by the auxiliary belt conveyor 118 from droppingthrough a gap in the end plate 112. Edges on the side of the cartonpickup port 104 of the end plate 112 are connected to each other throughthe end plate 132. An upper edge of the end plate 132 is in contact withthe bottom face of the pickup port guide plate 130.

The upper guide plate 146 is held below the actuator supporting base 124such that it is capable of rising or falling so as to form the cartonpickup port 104.

An edge on the side of the carton pickup port 104 of the upper guideplate 146 is provided with upper pawls 134, 136 for holding an upperedge portion of the sack carton C as shown in FIG. 8. On the other hand,an edge on the side of the carton pickup port 104 of the pickup portguide plate 130 is provided with lower pawls 138, 140 for holding alower edge portion of the sack carton C. Further, side pawls 142, 144for gripping a side edge portion of the sack carton C are provided at orin the vicinity of an end edge (hereinafter referred to as front end) onthe side of the carton pickup port 104 of each of the reference sideguide member 110A and the moving side guide member 110B.

The side pawls 142, 144 can be provided at a front end of each of thereference guide member 110A and the moving side guide member 110B.However, if the sack carton C has a header C2 projecting from the flapportion C12, as shown in FIG. 12, preferably, the side pawls 142 and 144are so provided that both the side pawls 142 and 144 are retracted about1 to 10 mm from the front end and that a distance d1 from the front endof the side pawl 142 is larger than a distance d2 from the front end ofthe side pawl 144. Because the flap portions C12, C14 are retracted atsubstantially an equal angle relative to a pickup direction if the sidepawls 142, 144 are provide on the aforementioned position, the sackcarton C can be picked up easily in the vicinity of the carton pickupport 104.

The structure of the upper pawl 134 and an upper guide plate 146, whichwill be described later, and their surrounding portion are shown in FIG.20. FIG. 20A indicates a side view of the upper guide plate 146, FIG.20B indicates a top view and FIG. 20C indicates a view on the side ofthe carton pickup port 104 or a front view.

As shown in FIGS. 19 and 20, the upper guide plate mounting portion 122comprises an actuator 148 which is fixed such that an actuatorsupporting base 124 is passed through an opening portion provided on afront edge of the actuator supporting base 124 in order to lift theupper guide plate 146 up and down and a fixing member 150 for fixing theactuator 148 at the aforementioned position of the actuator supportingbase 124.

A rod-like ram member 148A and an auxiliary ram member 148B areprojected from a bottom face of the actuator 148. The upper guide plate146 is fixed to a bottom end of each of the ram member 148A and theauxiliary ram member 148B. The actuator 148 incorporates various kindsof actuator mechanisms for hydraulic pressure, air pressure and ballscrews. The ram member 148A is raised and dropped by the actuatormechanism. The auxiliary ram member 148B is a guide member which isprovided adjacent to the ram member 148A for guiding the upper guideplate 146 in the vertical direction in order to prevent the upper guideplate 146 from rotating around the ram member 148A. If the ram member148A rises or falls, the upper guide plate 146 is raised or dropped.

A carton arranging plate 149 is provided substantially in parallel tothe upper guide plate 146 below the upper guide plate 146. A rubberplate 149A is fixed on a front edge of the carton arranging plate 149 inorder to protect the sack carton C from slipping relative to the cartonarranging plate 149.

An actuator 152 for lifting up and down the carton arranging plate 149is fixed on a top face of the upper guide plate 146 through a fixingmember 151. By moving the carton arranging plate 149 up and down by theactuator 152, heights of the upper edges of the sack cartons C can bearranged in line.

A bearing member 154 having a horizontal rotation axis is fixed on afront edge on the top face of the upper guide plate 146 and the upperpawl 134 is pivoted by a bearing member 154 so that its bottom portionis projected about 1 to 3 mm below an upper guide plate 146. Therefore,the upper pawl 134 rotates to approach or leave the front edge of theupper guide plate 146 as indicated with two-dot chain line in FIGS. 20Ato 20C.

As shown in FIG. 20, a disc-like load sensor 156 is fixed between thebearing member 154 on the top face of the upper guide plate 146 and theactuator 152. A load transmission arm 158 for transmitting a load to theload sensor 156 is provided backward above a portion pivoted by thebearing member 154 on the rear face of the upper pawl 134 or on a faceon the side in which the actuator 152 is provided. The upper pawl 134,the load transmission arm 158 and the load sensor 156 correspond topressure detecting means in the box body supplying unit of theinvention.

If a pressure is applied to the upper pawl 134 from the sack carton C,as indicated with two-dot chain line in FIG. 20A, a portion of the sameupper pawl 134 below its portion pivoted by the bearing portion 154 inthe upper pawl 134 is rotated forward while a portion above theaforementioned portion is rotated backward. Here, because the loadtransmission arm 158 is fixed to a portion above the aforementionedportion of the upper pawl 134 as described above, it is pressed backwardby the upper pawl 134 and rotated downward, so as to press the loadsensor 156. Consequently, the pressure is detected by the load sensor156.

The upper guide plate 160 is also a height direction guide memberabutted on an upper edge of the sack carton C for guiding the sackcarton C. As shown in FIGS. 19 and 21, the upper guide plate mountingportion 120 comprises an actuator 162 which is provided to oppose theactuator 148 at the opening portion of the actuator supporting base 124so that the upper guide plate 160 is disposed adjacent to the upperguide plate 146 in order to lift up and down the upper guide plate 160and a bracket 161 for fixing the actuator 162 onto an actuatorsupporting base 124 at the aforementioned position. As described above,the upper guide plate 160 is mounted on the actuator supporting base 124through the upper guide plate mounting portion 120 so that it is capableof being lifted up and down.

The plate-like upper pawl 136 projected downward is fixed at a front endof the upper guide plate 160. Preferably, a projection amount of theupper pawl 136 is 1 to 3 mm.

FIG. 22 shows the structure of the lower pawl 138 and its surroundingportion. FIG. 22A indicates a front view of the lower pawl 138 and FIG.22B indicates a side view thereof.

As shown in FIG. 22, a bearing member 164 for pivoting the lower pawl138 around a horizontal rotation axis is fixed on a front face of theend plate 132. When no load is applied, a top end of the lower pawl 138is projected 1 to 3 mm from the top face of the pickup port guide plate130.

A load sensor fixing plate 168 is fixed below the end plate 132 and aload sensor 166 for detecting a pressure applied to the lower pawl 138from the sack carton C is fixed on the load sensor fixing plate 168 sothat it opposes a bottom end portion of the lower pawl 138. The lowerpawl 138 and the load sensor 166 correspond to a pressure detectingmeans in the box body supplying apparatus of the invention.

If a pressure is applied from the sack carton C to the lower pawl 138,as indicated by two-dot chain line in FIG. 22, a portion above a portionpivoted by the bearing member 164 of the lower pawl 138 is rotatedforward while a portion below that portion is rotated backward.Therefore, the bottom end portion of the lower pawl 138 presses the loadsensor 166. Consequently, the pressure applied from the sack carton C tothe lower pawl 128 is detected by the load sensor 166.

FIG. 24 shows positions of the upper pawls 134, 136 and the side pawls142, 144 for supplying the sack cartons C of various shapes and sizes inthe carton supplying shoot 100 shown in FIGS. 17 to 19.

As shown in FIG. 24, the upper guide plate 146 and the upper guide plate160 are lifted up and down by the actuator 148 and the actuator 162depending on the height of the upper edge of the sack carton C, so thatthe bottom faces of the carton arranging plates 149, 160 abut on theupper edge of the sack carton C.

Further, the moving side guide member 110B moves in a directionapproaching or leaving the reference side guide member 110A so as toabut on the side edge of one flap portion of the sack carton C.

The carton supplying shoot 100 includes a transporting velocity controlsystem 170 for controlling the transfer velocities of the main beltconveyor 108 and the auxiliary belt conveyor 118 based on a signal fromthe load sensors 156, 166 as shown in FIG. 25. The transporting velocitycontrol system 170 corresponds to box body feeding control meansincluded by the box body supplying apparatus of the invention.

The transporting velocity control system 170 comprises an amplifier 172for amplifying a voltage output from the load sensor 156, an amplifier174 for amplifying a voltage output from the load sensor 166, a meterrelay 176 for controlling output voltages amplified by the amplifiers172, 174 with a reference voltage, a meter relay 176 for controlling asequencer 178 based on a result of the aforementioned comparison and asequencer 178 for controlling a belt conveyor drive unit 108C based on acontrol instruction from the meter relay 176.

As shown in FIG. 26, the sequencer 178 compares output voltage V1 whichis output from the load sensor 156 and amplified by the amplifier 174and output voltage V2 which is output from the load sensor 166 andamplified by the amplifier 172 with reference voltage V. Then, one offollowing four sequences indicated below is executed depending on therelation between the output voltage V1, output voltage V2 and thereference voltage V.

If both the output voltage V1 and output voltage V2 are below thereference voltage V, no pressure over the reference pressure is detectedby the load sensors 156, 166 so that the sequencer 178 judges that nopressure higher than the reference pressure is applied to the upper pawl134 and the lower pawl 138.

Therefore, the sequencer 178 turns on the motor 108D of the beltconveyor drive unit 108C, the first clutch 108E and the second clutch108F.

Consequently, both the drive rollers 108A and 118A are driven so thatthe main belt conveyor 108 and the auxiliary belt conveyor 118 are bothdriven at the same transfer velocity. Therefore, the sack carton C istransported to the carton pickup port 104 by the main belt conveyor 108and the auxiliary belt conveyor 118.

If the output voltage V1 is higher than the reference voltage V and theoutput voltage V2 is below the reference voltage V, the load sensor 156for detecting a pressure of the upper pawl 134 detects a pressure higherthan the reference pressure and then the sequencer 178 judges that thesack carton C is inclined as if the top edge of the sack carton C fallsforward or the sack carton C falls down forward at the supplying shootfront end portion 106.

Therefore, the sequencer 178 turns on the motor 108D and the secondclutch 108F of the belt conveyor drive unit 108C and turns off the firstclutch 108F so as to stop the drive roller 108A while rotating only the118A. Consequently, transporting by the main belt conveyor 108 isstopped and only transporting by the auxiliary belt conveyor 118 iscontinued. Thus, the bottom edge of the sack carton C is transported tothe carton pickup port 104 at the supplying chute front end portion 106so as to eliminate the forward inclination of the sack carton C.

If the output voltage V1 is below the reference voltage V while theoutput voltage V2 is higher than the reference voltage V, the loadsensor 166 for detecting a pressure of the lower pawl 138 detects apressure over the reference voltage and therefore the sequencer 178judges that the sack carton is inclined as if the bottom edge of thesack carton C falls forward, that is, the sack carton C falls backwardat the supplying shoot front end portion 106.

Therefore, the sequencer 178 turns on the motor 108D and the firstclutch 108F of the belt conveyor drive unit 108C and turns off thesecond clutch 108F so as to stop the drive roller 118A while rotatingonly the drive roller 108A. Consequently, only transporting by the mainbelt conveyor 108 is continued and transporting by the auxiliary beltconveyor 118 is stopped. As a result, the bottom edge of the sack cartonC is stopped at the supplying shoot front end portion 106 and the upperhalf portion of the sack carton C is pressed forward by a pressuresupplied from the main belt conveyor 108 so as to eliminate the backwardfalling.

If both the output voltage V1 and the output voltage V2 are higher thanthe reference voltage V, the load sensors 156, 166 detect a pressuresover the reference pressure and therefore, the sequencer 178 judges thatthe sack carton C is pressed against the upper pawl 134 and the lowerpawl 138 by an excessive pressure at the supplying chute front endportion 106.

Thus, the sequencer 178 turns off the motor 108D of the belt conveyordrive unit 108C, the first clutch 108F and the second clutch 108F so asto stop both the drive rollers 108A, 118A. Because the sack carton C ispicked up one by one continuously from the carton pickup port 104 bymeans of the carton supplying portion 200, the quantity of the sackcartons C at the supplying chute front end portion 106 is decreased, sothat a condition in which an excessive supply pressure is applied to theupper pawl 134 and the lower pawl 138 is eliminated.

FIGS. 27 and 28 show another example of the carton supplying chute. Thesame reference numerals in FIGS. 27 and 28 as in FIGS. 17 to 19 indicatethe same components as those in those Figures.

The carton supplying chute 101 shown in FIG. 27 is a carton supplyingchute according to an aspect in which the auxiliary belt conveyor 118 inthe carton supplying chute 100 is omitted and the pickup guide plate 130is extended up to the vicinity of the drive roller 108A.

A transporting velocity control system 171 is equal to the transportingvelocity control system 170 of the carton chute 100 in that it comparesthe output voltage V1 from the load sensor 156 and the output voltage V2from the load sensor 166 with the reference voltage V so as to controlthe sequencer 178 based on a result of the aforementioned comparison.However, this is different from the transporting velocity control system170 in that when any one of the output voltage V1 and the output voltageV2 is higher than the reference voltage V, the sequencer 178 turns offboth the motor 108D and the first clutch 108E in the same manner as whenboth the output voltage V1 and the output voltage V2 are higher than thereference voltage V.

The carton supplying chute 101 has the same configuration as the cartonchute 100 except the above-described points.

In the carton supplying chute 103 shown in FIG. 17, the supplying chutefront end portion 106 is formed vertically and the carton pickup port104 is directed downward. Further, the pickup port guide plate 130 isdisposed along the vertical direction from the vicinity of the driveroller 108A toward the carton pickup port 104. Further, a transportingdirection conversion guide 131 for guiding the sack carton C transportedby the main belt conveyor 108 toward the carton pickup port 104 in thevertical direction is provided so as to oppose the main belt conveyor108 and the pickup port guide plate 130. The transporting directionconversion guide 131 forms a square rod like vertical duct 107 forguiding the sack carton C downward in the vertical direction with thepickup port guide plate 130 at the supplying chute front end portion106.

The carton supplying chute 103 has the same configuration as the cartonsupplying chute except these points.

The transporting velocity control system 173 has the same configurationas the transporting velocity control system 171 included by the cartonsupplying chute 101 and the sequencer 178 controls the belt conveyordrive unit 108C according to the same sequence.

(B) Carton Supplying Portion

FIG. 29 shows an entire structure of a carton supplying portion 200.

As shown in FIG. 29, the carton supplying portion 200 corresponds to abox body supplying means in the box body supplying apparatus of theinvention and comprises a rotation shaft 202 which rises at an angle of45° relative to a horizontal plane toward the cartoner 400, a pair ofsuction heads 204 which is provided on a flat plane including therotation shaft 202 for sucking and holding the sack carton C along asuction plane which is a virtual plane inclined at an angle of 45°relative to the rotation shaft 202, in other words, a virtual plane in ahorizontal or vertical direction, and a suction head supporting portion206 supporting a suction head 204 rotatably around the rotation shaft202. In the meantime, the aforementioned suction plane is indicated withtwo-dot chain line in FIG. 29.

An index unit 208 for rotating the rotation shaft 202 intermittently anda motor 210 for supplying the index unit with a rotation force areprovided at a root of the rotation shaft 202.

The suction head 204 corresponds to box body holding means included bythe box body supplying means of the invention, and the rotation shaft202, the suction head supporting portion 206, the index unit 208 and themotor 210 correspond to a holding portion moving means included by thebox body supplying means.

The suction head 204 is pivoted by a suction head supporting portion 206on the shaft 212 provided in parallel to the suction plane.

FIGS. 30 to 34 show the detail of the structure of the suction head 204and its surrounding portion.

The suction head supporting portion 206 comprises a suction headsupporting plate 206A fixed on the rotation shaft 202 at its centralportion, a pair of first holding member 206B whose end is fixed to bothend portions of the suction head supporting plate 206A and a pair ofsecond holding members 206C whose end is fixed to a portion nearer thefront end portion than the suction head supporting plate 206A on therotation shaft 202.

A pair of the shafts 212 are provided and each of them is held at anangle of 45° relative to the rotation shaft 202 by the first holdingmember 206B and the second holding member 206C.

An end of a crank member 212A is fixed on an end on the side of thefirst holding member 206B on the shaft 212. A spring 212B for urging thecrank member 212A in a direction rotating the shaft 212 so as to turnthe suction head 204 upward is provided between the crank member 212Aand the first holding member 206B. A crank pushing member 230 forpushing the crank member 212A from downward and rotating the suctionhead 204 downward is provided adjacent to a bottom portion of the otherend portion of the crank member 212A. Unless the crank member 212 ispushed by the crank pushing member 230 as indicated with two-dot chainline in FIG. 34, the suction head 204 is directed upward by an urgingforce from the spring 212B. On the other hand, if the crank member 212Ais pushed by the crank pushing member 230 from downward, the shaft 212is rotated downward resisting the urging force of the spring 212B asindicated with a solid line in FIG. 34, so that the suction head 204stops in a condition in which it is inclined at an angle of about 40°relative to a horizontal plane and then opposes the carton pickup port104 in the carton supplying chute 100.

As shown in FIGS. 30 to 34, the suction head 204 comprises a frame body214 fixed to the rotation shaft 212 and a group of suction cups 218 andfurther includes a carton receiving portion 216 which slides along aslide rail 220 to be described later, provided inside the frame body 214to advance or retract relative to the suction plane.

The frame body 214 comprises side plates 214A, 214B which are fixed onthe shaft 212 inside of the portion held by the first holding member206B and the second holding member 206C for forming a side wall of theframe body 214 and guide plates 214C, 214D which form a ceiling plateand a bottom plate of the frame body 214, are projected from the sideplates 214A, 214B forward or in the direction toward the suction planeand guides the sack carton C toward the carton receiving portion 216.Here, the side plate 214A is a side plate adjacent to the first holdingmember 206B and the side plate 214B is a side plate adjacent to thesecond holding member 206C.

As shown in FIGS. 30, 31 and 33, an end of a slide rail mounting member214E is fixed on a portion inside of the frame body 214 on the shaft 212such that it is extended in parallel to the side plates 214A and 214Band in a direction parting from the suction plane. A slide rail 220 forguiding the carton receiving portion 216 in the advancement/retractiondirection in cooperation with a slide guide member 222, which will bedescribed later, is fixed on a top face of the slide rail mountingmember 214E. A slide guide receiver 214F for receiving the slide guidemember 222 from backward is fixed on the other end of the slide railmounting member 214E.

As shown in FIGS. 30 to 34, the carton receiving portion 216 comprises agroup of the suction cups 218 for sucking and holding the sack carton Cat an end thereof, a suction cup mounting plate 216A which is providedin parallel to the shaft 1212F or holding the suction cup 218 slidablyin the advancement/retraction direction, guide plates 216B, 216C whichare provided on upper and lower edges of the suction cup mounting plate216A and projected forward and a suction cup pressing member 216D whichis fixed on the other end portion of the suction cup 218 and pressedforward by a first suction cup receiving drive unit 240 to be describedlater so as to advance or retract the carton receiving portion 216 andthe suction cup 218. A pressing pin 216E for receiving a pressing forcefrom the suction cup receiving drive unit 240 is projected from thecentral portion of the cup pressing member 216D.

In the suction cup 218, a trumpet like cup portion 218A for sucking andholding the sack carton C is formed at an end thereof and a tubularportion 218B extending from the cup portion 218A to the other end isformed at the other end. Further, a spring 218C for urging the suctioncup 218 backward is mounted between the suction cup mounting plate 216Aand the suction cup pressing member 216D in the suction cup 218.

As shown in FIGS. 30 to 34, an end of a slide guide connecting member224 which connects the carton receiving portion 216 with the slide guide222 is coupled to a portion adjacent to a group of the suction cups 218on a face opposite to a side in which the cup portion 218A is open ofthe suction cup mounting plate 216A. The other end portion of the slideguide member 224 is fixed to the slide guide 222 and coupled to thepressing portion 226. The pressing portion 226 is projected to anopposite direction to the side in which the slide rail 220 of the sliderail mounting member 214E is fixed and advances or retracts the cartonreceiving portion 216 by receiving a pressing force from a suction cupmounting drive unit 260, which will be described later.

A spring 228 for urging the carton receiving portion 216 in a directionparting from the suction plane is provided between the rear end portionof the slide guide member 224 and the slide guide receiver 214F.

A projecting portion 216F projecting forward is formed on an oppositeside of the slide guide member 224 across the suction cup 218 in theguide plate 216B.

As shown in FIGS. 29, 35 and 36, a suction cup receiving drive unit 240and a suction cup mounting drive unit 260 for advancing or retractingthe suction head 204 are provided adjacent to the rotation shaft 202 andthe index unit 208. When the suction head 204 is located at a cartonreceiving position opposing the carton pickup port 104 of the cartonsupplying chute 100 as shown in FIG. 35, the suction cup receiving driveunit 240 advances or retracts the suction head 204. On the other hand,when the suction head 204 is located at a carton mounting positionopposing the carton opening forming portion 6 in the cartoner 400 asshown in FIGS. 29 and 36, the suction cup mounting drive unit 260advances or retracts the suction head 204.

As shown in FIGS. 35 and 36, when the suction head 204 is located at acarton receiving position, a receiving drive force transmission unit 280for transmitting a pressing force from the suction cup receiving driveunit 240 to the pressing pin 216E of the suction cup pressing member216D is provided on each of both faces of the suction head supportingplates 206A.

The receiving drive force transmission unit 280 comprises a pressing rod282 which presses the pressing pin 216E of the suction head 204 towardthe carton pickup port 104 with a pressing force from the suction cupreceiving drive unit 240, a pressing rod supporting member 284 having aleg portion 284A fixed to the suction head supporting plate 206A and forsupporting the pressing rod 282 slidably relative to the pressing pin216E and a spring 286 for urging the pressing rod 282 in a directionparting from the pressing pin 216E.

The suction cup receiving drive unit 240 comprises a receiving drive rod242 for pressing the pressing pin 216E through the pressing rod 282, areceiving drive rod supporting member 244 for supporting the receivingdrive rod 242 slidably along the axial direction at an angle inclined at40° upward from a horizontal plane, a reciprocating rod 246 forreciprocating vertically as indicated with an arrow a in FIG. 35 and abell crank mechanism 248 which is swung as indicated with an arrow b inthe same Figure for transmitting a motion of the reciprocating rod 246to the receiving drive rod 242.

As shown in FIG. 36, the suction cup mounting drive unit 260 comprises amain drive rod 262 which reciprocates, a drive rod supporting member 264for supporting the main drive rod 262 reciprocatingly, an auxiliarydrive rod 266 which is provided in parallel to the main drive rod 262and reciprocates integrally with the main drive rod 262, a linkingmember 268 for linking the main drive rod 262 with the auxiliary driverod 266 at the end portion and a drive crank 270 which is connectedrotatably to the auxiliary drive rod 266 and reciprocates the auxiliarydrive rod 266 around the rotation shaft 272.

In the suction cup mounting drive unit 260, the swing motion of thedrive crank 270 is converted to a reciprocating motion indicated with anarrow c in FIG. 36 by the auxiliary drive rod 266. The reciprocatingmotion of the auxiliary drive rod 266 is transmitted to the main driverod 262 through the linking member 268 so that the main drive rod 262reciprocates with the auxiliary drive rod 266. Consequently, the maindrive rod 262 presses the pressing portion 226 forward at apredetermined cycle so as to bring the suction head 204 near the cartonopening forming portion 6.

(C) Operation

If a predetermined quantity of the sack cartons C are accommodated inthe carton supplying chute 100 and the main belt conveyor 108 is driven,the sack carton C is moved to the supplying chute front end portion 106.

In the supplying chute front end portion 106, the sack carton C tries tobe moved further toward the carton pickup port 104 by the auxiliary beltconveyor 118. Therefore, at the carton pickup port 104, the sack cartonC is pressed by the upper pawls 134, 136 and the lower pawls 138, 140 sothat a pressure along the direction of picking out the sack carton C isapplied to the upper pawls 134, 136 and the lower pawls 138, 140. Theaforementioned pressure is detected by the load sensors 156, 166 andthen, the feedings of the main belt conveyor 108 and the auxiliary beltconveyor 118 are controlled by the transporting velocity control system170 so that the aforementioned pressure is below a predetermined value.

Since as shown in FIGS. 29, 34 to 36, a pair of the suction heads 204included by the carton supplying portion 200 are disposed symmetricallyacross the rotation shaft 202, when one is located at a carton receivingpreparation position directed upward, the other one is located at thecarton mounting position.

If the crank pushing member 230 rises and pushes the crank member 212Aincluded by the suction head 204, the suction head 204 is moved from thecarton receiving preparation position to a carton receiving positionopposing the carton pickup port 104 as shown in FIG. 34.

If the suction head 204 is located at the above-described cartonreceiving position, the receiving drive rod 242 in the suction cupreceiving drive unit 240 is projected toward the suction head 204 asshown in FIG. 35 so that the pressing pin 216E of the carton receivingportion 216 included by the suction head 204 is pressed through thepressing rod 282. Consequently, the carton receiving portion 216 ispushed out to the carton pickup port 104 and then, the cup portion 218Aof the suction cup 218 provided on the carton receiving portion 216 issucked to a side face of the sack carton C on a forward side of thecarton receiving portion 216 (hereinafter referred to as “forwardside”).

After the sack carton C is sucked by the suction cup 218, the receivingdrive unit 240 presses the carton receiving portion 216 inward of thesupplying chute front end portion 106 as shown in FIG. 37A.

If the carton receiving portion 216 is pressed, the sack carton C ispressed into the inside of the supplying chute 100.

With this condition, the carton arranging plate 149 is descended to thesack carton C by the actuator 152. Consequently, the second or third andfollowing sack cartons C from the most forward side are pressed and heldby the rubber plate 149A of the carton arranging plate 149. If theheights of the top edges of the sack cartons C are not in line, theheights of the top edges of the sack cartons C can be arranged bypressing the top edges of the sack cartons C by means of the cartonarranging plate 149.

If the sack carton C is pressed and held by the carton arranging plate149, the receiving drive rod 242 is moved in a direction leaving thesuction head 204 and then, as shown in FIG. 37C, the carton receivingportion 216 is departed from the carton pickup port 104 by an urgingforce from the spring 228. Since the carton receiving portion 216 leavesthe carton pickup port 104 drawing a S-shaped trajectory when viewedfrom a side as shown in FIG. 37D, the sack carton C on the most forwardside is taken out of the carton pickup port 104 with a condition that anopening is formed halfway.

An operation of the carton receiving portion when taking out the sackcarton C will be described further.

Since a projecting portion 216F is formed at a front end of the guideplate 216B provided on the carton receiving portion 216, if the cartonreceiving portion 216 approaches the sack carton C, first, theprojecting portion 216F is brought into contact with the sack carton Cas shown in FIGS. 39A and 38. Here, the projecting portion 216F isprovided corresponding to a position at a gap between the outside flapC22 provided on a side face a which is a side face which the suction cup218 of the sack carton C is sucked and the inside flap C20 provided on aside face b adjacent to the side face a. Therefore, the projectingportion 216F passes through a gap between the outside flap C22 and theinside flap C20 and abuts on the outside flap C22 provided on a sideface c opposing the side face a.

If the projecting portion 216F abuts on the outside flap C22, the cartonreceiving portion 216 advances from the above-described condition toinside of the supplying chute front end portion 106 and presses the sackcarton C into the inside of the supplying chute front end portion 106.When the sack carton C is pressed into the inside of the supplying chutefront end portion 106 by a predetermined amount, the sack carton C ispressed and held by the carton arranging plate 149 as described above.Consequently, the carton receiving portion 216 cannot advance further.Therefore, as shown in FIG. 39B, only the suction cup 218 projects fromthe suction cup mounting plate 216A and advances and then adheres to theside face a of the sack carton C by suction.

If the suction cup 218 adheres to the side face a of the sack carton Cby suction, the suction cup 218 is retracted by an urging force from thespring 218C while adhering to the sack carton C as shown in FIG. 39C.Therefore, the side face a is pulled by the suction cup 218 and movedtoward the suction cup mounting plate 216A, so that it abuts on edges ofthe guide plates 216B and 216C. When the side face a abuts to the edgesof the guide plates 216B, 216C, the outside flap C22 abuts on a frontend of the projecting portion 216F. Here, since the projecting portion216F is projected from the edges of the guide plates 216B, 216C, theoutside flap C22 moves in a direction leaving the side face a andtherefore, the side face c adjacent to the outside flap C22 moves in adirection leaving the side face a. Consequently, a gap is formed betweenthe side face a and the side face c, so that a slight opening is formedin the sack carton C.

By bringing the carton receiving portion 216 apart from the cartonpickup port 104, the sack carton C can be taken out of the carton pickupport 104 with a condition that a slight opening is formed as shown inFIG. 39C.

FIG. 40 shows the details of an action of the suction cup 218 when thecarton receiving portion 216 leaves the carton pickup port 104 and anaction of the sack carton C accompanying this. Referring to FIG. 40, asolid line indicates the position of the suction cup 218 when it adheresto the sack carton C by suction while a two-dot chain line indicates theposition of the suction cup 218 when the carton receiving portion 216leaves the carton pickup port 104.

As shown in FIG. 40, the suction cup 218 keeps the sack carton C openwhile drawing a substantially S-shaped trajectory at a side view afterit adheres to the sack carton C by suction and after that, moveslinearly in a direction leaving the suction pickup port 104.

Therefore, the side face a moves toward the forward side, that is,downward to the left in FIG. 40 and at the same time, moves downward.Thus, a folding portion a located between the side face a and the sideface b moves downward and toward the forward side like the side face a.Then, a folding portion d which opposes the folding portion a forming atop edge of the sack carton C moves downward. On the other hand, afolding portion b which is located between the side face b and the sideface c forming a bottom edge of the sack carton C cannot move downwardbecause it abuts the pickup port guide plate 130. Thus, as indicatedwith arrows, the side face b rotates to the forward side around thefolding portion b and the side face c rotates to an opposite side, thatis, upward to the right in FIG. 40. Therefore, since the side face a andthe side face c move in directions of leaving each other, an opening isformed in the sack carton C halfway and the top edge escapes from theupper pawls 134, 136. By bringing the suction cup 218 apart from thecarton pickup port 104 further from this condition, the suction cup Ccan be taken out without any firm contact with the upper pawls 134, 136and the lower pawls 138, 140.

If the sack carton C is taken out of the carton pickup port 104, thecrank pushing member 230 descends and then, the crank member 212 isrotated counterclockwise by an urging force from the spring 212B asindicated with two-dot chain line in FIGS. 34 and 35 and is returned toa position before the carton is received. Therefore, the suction head204 is directed upward again and returned to the carton receivingpreparation position.

If the shaft 202 is rotated by 1800 from this condition, the suctionhead 204 moves from the carton receiving preparation position to thecarton mounting position.

As shown in FIG. 36, in the carton mounting position, the pressingportion 226 of the suction head 204 moves to a position opposing thefront end of the main drive rod 262 in the suction cup mounting driveunit 260.

Therefore, if the suction cup mounting drive unit 260 is actuated andthe main drive rod 262 presses the pressing portion 226 toward thecarton opening forming portion 6 of the cartoner 400, the cartonreceiving portion 216 is moved toward the carton opening forming portion6 through the slide guide connecting member 224 fixed on the pressingportion 226. Here, because in the carton receiving portion 216, thecartoner C adheres to the suction cup 218 by suction, the cartoner C ismounted on the carton opening forming portion 6 after an opening isformed by the opening forming unit 6A halfway.

1-3 Characteristic of the Cartoner and Carton Supplying Unit Accordingto a First Embodiment

In the carton supplying unit 2, the sack carton C is accommodated in thecarton supplying chute 100 such that it is located sideway of the flapportions C12, C14. Therefore, even a carton having a large header at itsone end portion or an elongated carton can be loaded easily. Further,even if a carton, in which the flap portions C12, C14 have anoverlapping portion and a non-overlapping portion in a folding conditionand there is a difference in thickness between the folding portion a andthe folding portion d, is loaded, the sack carton C is held on thecarton pickup port 104 at right angle to the pickup direction.Consequently, the sack carton C is taken out stably.

Further, the sack carton C is taken out stably because the main beltconveyor 108 and the auxiliary belt conveyor 118 are controlled so thatpressure applied to the upper pawls 134, 136 and the lower pawls 138,140 are within a predetermined range.

Further, because as described above, when the sack carton C is takenout, the second, third and following cartons from the most forward sideare pressed by the carton arranging plate 149 and the sack carton C istaken out with a slight opening formed, the sack carton C is preventedfrom making into firm contact with the upper pawls 134, 136 and thelower pawls 138, 140 thereby protecting from a damage. Further, even ifan old carton or a warped carton is loaded, the sack carton C is takenout smoothly.

Further, because the carton supplying unit 2 has not only the mainconveyor 108 but also the auxiliary conveyor 118, cartons each having adifferent thickness can be fed to the carton pickup port 1104 Stably.

Additionally, because in the carton supplying portion 200, one of a pairof the suction heads is located at the carton receiving preparationposition relative to an axis inclined at 45° with respect to ahorizontal plane while the other one is fixed at the carton mountingposition line symmetrically to the former, reception of a carton fromthe carton supplying chute 100 and supply of the carton to the cartoner400 can be carried out in parallel.

Further, because the opening is formed in the carton halfway when thesack carton C is taken out, no failure occurs in the carton openingforming portion 6 of the cartoner 400.

Because the cartoner 400 utilizes the carton supplying unit 2 in orderto supply the cartons and the rotation table 4 for holding the sackcarton C is made of a pair of index table 4A and index table 4B whichare formed so as to be capable of approaching or leaving, it can copewith various shapes and lengths of the sack cartons flexibly.

Further, because the carton supplying unit 2, the carton opening formingportion 6, the plastic case-packed product packing portion 8, the upperlid constructing portion 10, the bottom lid constructing portion 12 andthe carton discharging portion 14 are disposed around the rotation table4, the entire apparatus can be constructed in a compact fashion.

Additionally, because the sack carton C is supplied to the cartonopening forming portion 6 with one of opening portions of both the endsfacing upward and the other one facing downward and after the opening isformed with this condition, the plastic case packed product is loadedthrough the opening portion facing upward without changing the postureof the sack carton C, the boxing and packaging can be carried outefficiently.

A Second Embodiment

Another example of a cartoner included in the boxing apparatus relatedto the present invention is shown in FIGS. 41 and 42.

A cartoner 402 related to the second embodiment is an example of acartoner incorporating a sack carton holding unit 350 and a sack cartonpick-up and supplying unit 300 in place of the carton supplying chute100 and the carton supplying portion 200 in the cartoner 400 related tothe first embodiment. As shown in FIGS. 41 and 42, the cartoner 402 hasthe rotating table 4, the carton opening forming portion 6, the plasticcase-packed product packing portion 8, the upper lid constructingportion 10, the bottom lid constructing portion 12 and the cartondischarging portion 14, all of which are the same as those incorporatedin the cartoner 400 of the first embodiment.

As shown in FIG. 43, the sack carton holding unit 350 is disposed so asto face the rotating table 4. The sack carton holding unit 350 comprisesa stocker 356 having a pair of guide plates 352 and 354 disposedlaterally, a bottom guide plate 358 that is provided between the guideplates 352 and 354 so as to provide a bottom of the stocker 356 and tobe adjustable of its height, an air cylinder 360 moving the guide plate354 so as to approach or part from the guide plate 352, a pair of guiderods 362 guiding the guide plate 354 when moving the guide plate 354 bythe air cylinder 360 and a pair of rod holding members 364 holding theguide rods 362 slidably.

In the sack carton holding unit 350, folded sack cartons C are stored inthe stocker 356. Then, the height of the bottom guide 358 is adjusted inaccordance with the height of the sack cartons C. At the same time, apiston of the air cylinder 360 is expanded or contracted in accordancewith the width of the sack cartons C to move the guide plate 354 so asto change the width and height dimensions of the stocker 356. Thus, thewidth and height dimensions of the stocker 356 can be adjusted inaccordance with a sack carton C having a different height or lateraldimension.

As shown in FIGS. 41 to 43, the sack carton pick-up and supplying unit300 is disposed between the index table 4A (4B) and the sack cartonholding unit 350. The sack carton pick-up and supplying unit 300functions to pick up the sack carton C folded and stored in the stocker356 and set the picked up sack carton C to the carton setting portion 42of the index tables 4A and 4B.

The sack carton pick-up and supplying unit 300 has a rotating table 302,suction cups 304 and 306 that are mounted on the rotating table 302. Thesuction cups 304 and 306 are disposed on the rotating table 302 with anaxis 312 of the rotating table 302 between them. The rotating table 302rotates intermittently around the axis 312 by 180 degrees so that one ofthe suction cups 304 and 306 faces the carton setting portion 42 of theindex table 4A and the other faces the stocker 356.

The suction cups 304 and 306 are fixed on sliders 316 and 318,respectively, the sliders 316 and 318 sliding on a linear guide 314fixed on the rotating table 302. The suction cups 304 and 306 are alsoconnected and urged by helical springs 320 so as to approach each other.

Outside of the rotating table 302, suction cup-driving levers 308 and310 are provided. The suction cup-driving levers 308 and 310 drive thesuction cups 304 and 306 against the urging forces of the helicalsprings 320 so that the suction cup 304 parts from the suction cup 306.The suction cup-driving levers 308 and 310 rotate with the rotatingtable 302. Additionally, the slider 316 on which the suction cup 304 isfixed and the slider 318 on which the suction cup 306 is fixed arepressed to the suction cup-driving levers 308 and 310, respectively bythe urging force from the helical springs 320.

The sack carton pick-up and supplying unit 300 operates as follows.

Firstly, the suction cup-driving lever 308 drives the suction cup 304 toapproach the stocker 356. Then, the suction cup 304 sucks a sack cartonC located at the front of the stocker 356.

Then, the rotating table 302 rotates in 180 degrees around the axis 312to and stands for a predetermined time so that the sack carton C suckedby the suction cup 304 stands at a position facing the carton settingportion 42 of the index tables 4A and 4B. The opening forming device 6Aopens the sack carton C in the time when the sack carton C is standingat said position. After the sack carton C is opened, the suction cup 304is moved toward the carton setting portion 42 and set therein by thesuction cup-driving lever 308. At the same time, the suction cup 306moves toward the stocker 356 and sucks a sack carton C located at thefront of the stocker 356.

A Third Embodiment

An adhesive-injection inspection system 3300 related to the thirdembodiment is an example an adhesive-injection inspection system thatcan be disposed close to hot melt adhesive injecting gun 20 and 22incorporated in the cartoner 400.

As shown in FIG. 44, the adhesive-injection inspection system 3300incorporates an optical fiber sensor 3302 disposed close to the hot meltadhesive injecting gun 20 with a hot melt adhesive injection path fromthe hot melt adhesive injecting gun 20 between then, an optical fibersensor 3304 disposed close to the hot melt adhesive injecting gun 22with a hot melt adhesive injection path from the hot melt adhesiveinjecting gun 22 between then, a logical control unit (PLC) 3306 whereinanalogue signal is input from the optical fiber sensors 3302 and 3304,and based on the input signal, determinates whether the hot meltadhesive is normally injected, a sensor amplifier 3308 amplifyinganalogue signal from the fiber sensor 3302 and input the amplifiedsignal into the logical control unit 3306 and a sensor amplifier 3310amplifying analogue signal from the fiber sensor 3304 and input theamplified signal into the logical control unit 3306.

FIGS. 45A and 45B show a top view and a side view of the hot meltadhesive-injecting gun 20 and the optical fiber sensor 3302,respectively.

As shown in FIGS. 45A and 45B, the optical fiber sensor 3302incorporates a light-emitting unit 3302A emitting light to the injectionpath of the hot melt adhesive injected from the hot meltadhesive-injecting gun 20 and is shown by an arrow b, a light-receivingunit 3302B receiving the light from the light-emitting unit 3302A, abase 3302C holding the light-emitting unit 3302A and the light-receivingunit 3302B.

The light-emitting unit 3302A and the light-receiving unit 3302B arefixed on the base portion 3302C so that a beam emitted from thelight-emitting unit 3302A hit a light-receiving device of thelight-receiving unit 3302B straightly.

A flange portion 3302D is provided at one end of the base portion 3302C.The flange portion 3302D is fixed on the cartoner 400 at a locationclose to the hot melt adhesive-injecting gun 20 by bolts 3302E and3302F. As shown in FIG. 45A by an arrow c, the base portion 3302D can berotated around the bolt 3302E with the bolt 3302F loosened. Thus, byrotating the base portion 3302C with the bolts 3302E and 3302F loosened,the path of the beam from the light-emitting unit 3302A to thelight-receiving unit 3302B can be adjusted to the injection path b.

FIGS. 46A and 46B show a top view and a side view of the hot meltadhesive-injecting gun 22 and the optical fiber sensor 3304,respectively.

As shown in FIGS. 46A and 46B, the optical fiber sensor 3304incorporates a light-emitting unit 3304A emitting light to the injectionpath of the hot melt adhesive injected from the hot meltadhesive-injecting gun 22 and is shown by an arrow d, a light-receivingunit 3304B receiving the light from the light-emitting unit 3304A, abase 3304C holding the light-emitting unit 3304A and the light-receivingunit 3304B.

An optical fiber sensor mount 3304D is fixed at its one end on thecartoner 400 at a location close to the hot melt adhesive-injecting gun22 by a pair of bolts 3304E at a root portion thereof so that a tipportion thereof extends toward the hot melt adhesive-injecting gun 22.The base portion 3304C is fixed on the tip portion of the optical fibersensor mount 3304D. At the root portion of the optical fiber sensormount 3304D, an adjusting bolt 3304F is provided adjacent to the bolts3304E for adjusting the height of the end portion of the optical fibersensor mount 3304D on which the base portion 3304C is mounted. Byturning the adjusting-bolt 3304F in the clockwise direction or thecounter clockwise direction to raise or lower the base portion 3304C,the optical axis of the beam from the light-emitting unit 3304A to thelight-receiving unit 3304B can be adjusted to the injection path d.

As shown in FIG. 44, the logical controlling device 3306 comprises ananalogue input unit 3306A, digital input unit 3306B, a digital outputunit 3306C and a CPU unit 3306D.

To the analogue input unit 3306A, analogue signal of light receptionintensity from the optical sensors 3302 and 3304 is input through thesensor amplifiers 3308 and 3310, respectively.

To the digital input unit 3306B, injection command to the hot meltadhesive injecting guns 20 and 22 (hereinafter, only referred to‘injection command’) from a controlling computer (not shown) controllingthe cartoner 400 is input.

The digital output unit 3306C outputs alarms 1 to 4 (bottom lid)relating to the hot melt adhesive injecting gun 22 and alarms 1 to 4(upper lid) relating to the hot melt adhesive injecting gun 20 on thecommand from the COU unit 3306D. These alarms are displayed on anappropriate device such as a display.

The CPU unit 3306D determinates whether hot melt adhesive is normallyinjected by the hot melt adhesive-injecting guns 20 and 22 on the basisof the analogue signal input to the analogue input unit 3306A and theinjection command input to the digital input unit 3306B and controls thedigital output unit 3306C to generate the above alarms on the basis ofthe determination thereof.

FIG. 47 shows a flow of information and a scheme for determination.

In FIG. 47, ‘injection command ON’ is a signal showing that the controlcomputer input a command to initiate injection and ‘injection commandOFF’ is a signal showing that the control computer input a command tostop injection to the cartoner 400.

Schemes for determination and for generating alarms 1 to 4 are describedbelow.

As shown in FIG. 47, when the signal ‘injection command ON’ is inputinto the CPU unit 3306D by the digital input unit 3306B at a step S2,the CPU unit 3306D reads the light reception intensity at the opticalfiber sensor 3302 through the analogue input unit 3306A as the ‘lightreception intensity at light transmittance t1’ at a step S4. The ‘lightreception intensity at light transmittance’ in FIG. 47 represents theabove-mentioned light reception intensity.

When the ‘light reception intensity at light transmittance t1’ is input,the CPU unit determinates whether the light reception intensity is notless than a predetermined value t0 at a step S6.

As shown in FIG. 48A, if the ‘light reception intensity at lighttransmittance t1’ is higher than the predetermined value t0, the datacan be interpreted that the light-emitting unit 3302A in the opticalfiber sensor 3302 emits light of sufficient intensity to thelight-receiving unit 3302B and that the light-receiving unit 3302Breceives the light normally and thus, the CPU unit 3306D determinatesthat both the optical fiber sensor 3302 and the sensor amplifier 3308function normally.

On the contrary, if the light reception intensity at light transmittancet1′ is equal to or lower than the predetermined value t0, the data meanthat there is a possibility that the intensity of the light from thelight-emitting unit 3302A is too weak, or that there would be somemalfunction in the light receiving device of the light-receiving unit3302B, or that hot melt adhesive has stuck on the light-receiving unit3302B and the beam from the light-emitting unit 3302A is interfered.There would also be possibly some malfunction in the sensor amplifier3308 and no analogue signal would not be input from the light-receivingunit 3302B into the analogue input 3306A. Thus, the CPU unit 3306Ddeterminates that there would be some malfunction at least at thelight-emitting unit 3302A, the light receiving unit 3302B and the sensoramplifier 3308. Based on said determination by the CPU unit 3306D, thedigital output unit 3306C outputs the alarm 3 indicating that theamplifying level of the sensor amplifier 31308 is too low, then, showsthe alarm 3 on a display (not shown).

When determining that the optical fiber sensor 3302 and the sensoramplifier 3308 function normally at the step S6, the CPU unit 3306Dcalculate an average A by averaging previous five data of ‘lightreception intensity at light transmittance t1’ at a step S8 and storethe average A into a memory.

At the hot melt adhesive injecting guns 20 and 22, there is some lagbetween the time when a command of injection is input and the time wheninjection of the hot melt adhesive is actually initiated. Thus, as shownin FIG. 47, when determining that the optical fiber sensor 3302 and thesensor amplifier 3308 function normally, at a step S10, after waitingfor 20 ms, the CPU unit 3306D read a light reception intensity at theoptical fiber sensor 3302. The ‘light reception intensity at injection’corresponds to said light reception intensity. After reading the ‘lightreception intensity at injection t2’, at a step S12, a level difference

that is a difference between the ‘light reception intensity at lightshading’ and the ‘light reception intensity at injection t2’ iscalculated and it is determined whether the level difference

is larger than a predetermined value

d at a step S14.

As shown in FIG. 49A, if the level difference

is larger than the predetermined value

d, the CPU unit 3306D determinates that the light-emitting unit 3302Aand the light-receiving unit 3302B in the optical fiber unit 3302 arefunctioning normally. On the other hand, as shown in FIG. 49B, if thelevel difference

is equal to or smaller than the predetermined value

d, it can be thought that the beam from the light-emitting unit 3302A isnot sufficiently shaded by the flow of hot melt adhesive injected fromthe hot melt adhesive injecting gun 20 or that the light receiving unit3302B is malfunctioned and generates photoelectric current even when thebeam from the light-emitting unit 3302A is sufficiently interrupted.Thus, the CPU unit 3306 determinates that at least one of thelight-receiving unit 3302B and the hot melt adhesive injecting gun 20are malfunctioned. Based upon said determination by the CPU unit 3306D,the digital output unit 3306C outputs the alarm 4 indicating that thelevel difference is too low, then displays the alarm 4 on the display.

When determining that both the light-receiving unit 3302B and the hotmelt adhesive injecting gun 20 are functioning normally, the CPU unit3306D calculate an average B by averaging previous five data of ‘lightreception intensity at injection t2’ and store the average B in thememory.

Then, at a step S18, the CPU unit 3306D reads the averages A and B outof the memory and determinates a value obtained by adding the average Ato the average B and dividing by 2 as a threshold value tv. However, theprocess for determinating the threshold value tv based upon the averageA and the average B is mot limited in the above.

When the threshold value tv is determined at the step S18, the CPU unit3306D determinates whether the first ‘light reception intensity atinjection t2’ is lower than the threshold value. As shown in FIG. 50A,if the first ‘light reception intensity at injection t2’ is lower thanthe threshold value tv, the CPU unit 3306D determinates that the hotmelt adhesive is injected in a sufficient flow since it can be thoughtthat the beam from the light-emitting unit 3302A is sufficientlyinterrupted by the flow of the hot melt adhesive injected from the hotmelt adhesive injecting gun 20. On the other hand, as shown in FIG. 50B,the first ‘light reception intensity at injection t2’ is equal to orhigher than the threshold value tv, the CPU unit 3306D determinates thatthe hot melt adhesive is injected in an insufficient flow since it canbe thought that the beam from the light-emitting unit 3302A is notsufficiently interrupted by the flow of the hot melt adhesive injectedfrom the hot melt adhesive injecting gun 20. Then, based upon the abovedetermination by the CPU unit 3306D, the digital output unit 3306Coutputs the alarm 1 indicating that the hot melt adhesive is injected inan insufficient flow and stores said light reception intensity atinjection t2′ in the memory.

When determining that the hot melt adhesive is injected in a sufficientflow, the CPU unit 3306D waits for 10 ms and then, confirms that theinjection command is still ON at a step S22. If it is confirmed that theinjection command is still ON, at a step S24, the CPU unit 3306D readsout the ‘light reception intensity at injection t2’ through the analogueinput unit 3306A and determinates whether the hot melt adhesive isinjected in a sufficient flow or not at the step S20. Thus, the CPU unit3306D repeats the steps S20, S22 and S24 in an order of step S20, stepS22 and then step S24. When carrying out the steps S20, S22 and S24repeatedly, as shown in FIG. 51, if the ‘light reception intensity atinjection t2’ turns to be equal to or higher than the threshold valuetv, the CPU unit determinates that the flow of the hot melt adhesivebecomes smaller than a normal flow rate and then, the digital outputunit outputs the alarm 1.

When the injection command turns from ON to OFF, the CPU unit 3306Dstands without carrying out the next step. After passing 150 ms, whichis a time necessary for stopping injecting the hot melt adhesive afterthe injection command turns OFF, at a step S26, the CPU unit 3306D readout a light reception intensity at the optical fiber sensor 3302 as a‘light reception intensity at injection stoppage t3’ through theanalogue input unit 3306A. At a step S28, the CPU unit 3306Ddeterminates whether the ‘light reception intensity at injectionstoppage t3’ is higher than a reference value td, which is determinedseparately from the predetermined value t0 and has a value closer to the‘light reception intensity at light transmittance t1’ than the thresholdvalue tv.

As shown in FIG. 52, if the ‘light reception intensity at injectionstoppage t3’ is higher than the reference value td, the CPU unit 3306Ddeterminates that hot melt adhesive injection has stopped at the hotmelt adhesive injecting gun 20 without the hot melt adhesive cobwebbingsince it can be thought that there is nothing interrupting the beambetween the light-emitting unit 3302A and the light-receiving unit 3302Bat a step S28.

On the other hand, as shown in FIG. 53, if the ‘light receptionintensity at injection stoppage t3’ is equal to or lower than thereference value td, the CPU unit 3306D determinates that cobwebbing ofthe hot melt adhesive takes place at the hot melt adhesive injecting gun20 since it can be thought that there is exist between thelight-emitting unit 3302A and the light-receiving unit 3302B a flow ofthe hot melt adhesive hugely interrupting the beam. Then, on the basisof the above determination of the CPU unit 3306D, the digital outputunit 3306C outputs the alarm 2 indicating the existence of cobwebbingand stores said ‘light reception intensity at injection stoppage t3’ inthe memory.

Thus, the scheme of determination and outputting alarms is described.For the hot melt adhesive injecting gun, the CPU 3306 carries outdetermination and outputting of alarms in the same scheme from inputfrom the optical fiber sensor 304.

According to the adhesive-injection inspection system 3300 of the thirdembodiment, it can be detected whether hot melt adhesive is normallyinjected at the hot melt adhesive injecting guns 20 and 22. When hotmelt adhesive is not normally injected, alarms are output and thecartoner stops its operation. Thus, it can be prevented that a cartonhaving flap portions C12 not glued to an outside flap C18 and havingupper lid C8 left open or a carton having outside flaps C22 not glued toeach other and having a bottom lid C10 left open is discharged from thecarton discharging portion 14 of the cartoner 400.

Additionally, it can be detected whether cobwebbing does not take placeafter stopping hot melt adhesive injection and thus, it can be preventedthat hot melt adhesive sticks out of an intentioned area of a sackcarton C and deteriorate its quality and that the cartoner 400, the hotmelt adhesive injecting gun 20 and the hot melt adhesive injecting gun22 are stained with injected adhesive. It is also prevented that theoptical fiber sensors 3302 and 3304 are stained with hot melt adhesiveand sensitivity thereof deteriorates.

Further, malfunction of the optical fiber sensors 3302 and 3304 andsensor amplifies 3308 and 3310 can be easily detected.

Furthermore, different alarms are displayed for different malfunctionand thus, operators can learn a type of malfunction from the type ofdisplayed alarm and can take an appropriate measure swiftly.

A Fourth Embodiment

An example of a plastic case packed product supplying unit incorporatedin the packaging system of the present invention is described in thefollowing.

A plastic case packed product supplying unit 800 that relates to thefourth embodiment is an example of the plastic case supplying unit 8B inthe cartoner 400 and is located above the cartoner 400 as shown in FIG.54.

As shown in FIG. 55, the plastic case packed product supplying unit 800comprises a plastic case packed product arraying portion 810 which islocated above the cartoner 400 and arranges the plastic case packedproduct P and the plastic case packed product P′ according to apredetermined array, a plastic case packed product introducing portion820 for supplying the plastic case packed product P and the plastic casepacked product P′ arrayed by the plastic case packed product arrayingportion 810 to the cartoner 400, a first plastic case packed productsupplying line 830 for supplying the plastic case packed product Pmanufactured by the winding machine 900 to the plastic case packedproduct arraying portion 810 and a second plastic case packed productsupplying line 840 for supplying the plastic case packed product P′ froma plastic case packed product silo 850 accommodating the plastic casepacked product P′ of a different type from the plastic case packedproduct to the plastic case packed product arraying portion 810.

The first plastic case packed product supplying line 830 and the secondplastic case packed product supplying line 840 correspond to a firstintroduction line and a second introduction line included by thepackaging object supplying apparatus of the invention. Then, the plasticcase packed product arraying portion 810 corresponds to a packagingobject combination portion in the packaging object supplying apparatusand further corresponds to a distributing means. The plastic case packedproduct introducing portion 820 corresponds to a packaging objectintroduction portion in the packaging object supplying apparatus.

Hereinafter, respective components of the plastic case packed productsupplying unit 800 will be described.

1-1 First Plastic Case Packed Product Supplying Line

A first plastic case packed product supplying line 830, as shown inFIGS. 55, 56A and 56B, comprises a first horizontal conveyor 832 fortransporting the plastic case packed product P manufactured by thewinding machine 900, a vertical conveyor 834 which is located at an endportion on the downstream side with respect to a transporting directionof the first horizontal conveyor 832 and at right angle andsubstantially above the first horizontal conveyor 832, and a secondhorizontal conveyor 836 which is extended horizontally from a vertex ofthe vertical conveyor 834 toward the plastic case packed productarraying portion 810. a plastic case packed product direction conversionunit 838 for converting the direction of the plastic case packed productis provided between the vertical conveyor 834 and the second horizontalconveyor 836.

A pusher 835 for pushing the plastic case packed product P carried bythe first conveyor to the vertical conveyor 834 is provided between thefirst conveyor 832 and the vertical conveyor 834.

The first plastic case packed product supplying line 830 includes afolded pipe like plastic case packed product introduction duct 831 forintroducing the plastic case packed product manufactured by the windingmachine 900 onto the first conveyor 832.

Hereinafter, the structure of the respective components will bedescribed.

(A) First Horizontal Conveyor and Vertical Conveyor

The first horizontal conveyor 832 comprises a belt conveyor portion 832Afor carrying the plastic case packed product P and a pair of guideplates 832B which are provided on both sides of the belt conveyorportion 832A for holding the plastic case packed product P from falling.An end portion in the downstream of the first horizontal conveyor 832has a block type stopper 832C for stopping the plastic case packedproduct P carried by the belt conveyor portion 832A. The guide plate832B has a cutout in the vicinity of the stopper 832C in order toprevent the pusher 835 from obstructing pushing of the plastic casepacked product P by the pusher 835 to the vertical conveyor 834.

The vertical conveyor 834 includes a belt 834A provided substantiallyvertically and a shelf plate 834B provided at right angle to the frontface of the belt 834A and at a specified interval. A pair of guideplates 834C are provided on both sides of the belt 834A in order toprevent the plastic case packed product P from dropping to the right orthe left relative to transporting direction. As shown in FIG. 56, theplastic case packed product P is transported upward in a condition thatit is mounted on the shelf plate 834B.

The pusher 835 comprises a pusher member 835A for pushing the plasticcase packed product P and an air slider 835B for moving the pushermember 835A in a direction approaching the vertical conveyor 834 and ina direction leaving the vertical conveyor 834.

As shown in FIG. 56B, an inclined chute 833 descending toward thevertical conveyor 834 is disposed between the first horizontal conveyor832 and the vertical conveyor 834. Above and the below of the inclinedchute 833, a plastic case packed product detecting sensor 833A detectingwhether the inclined chute 833 is filled with plastic case packed casesP is provided.

The inclined chute 833 is supplied with plastic case packed products Pconveyed by the first horizontal conveyor 832 by the pusher 835 notsynchronously with the vertical conveyor.

The self plates 834B are provided in a pitch that one plastic casepacked product can be inserted but 2 or more plastic cases cannot beinserted between any two adjacent self plates 834B. Thus, plastic casepacked products sliding down the inclined chute 833 is picked up one byone and not synchronously by the vertical conveyor 834.

(B) Plastic Case Packed Product Direction Conversion Unit

The plastic case packed product direction conversion unit 838 includes achute portion 838A which forms a downward pitch from the verticalconveyor 834 to the second horizontal conveyor 836 as shown in FIGS. 57and 58. Guide plates 838B are provided on both sides of the chuteportion 838A. In the meantime, the guide plate 838B located forwardrelative to this paper surface is omitted in FIG. 57.

End portions on the upstream side and downward side relative to thetransporting direction of the chute portion 838A are formed in a widthenough large to allow the plastic case packed product P carried by thevertical conveyor 834 to pass through in a condition that it lies atright angle to the transporting direction. A plastic case packed productdirection conversion unit 838C larger than both ends is formed in thecenter of the chute portion 838A.

A plastic case packed product direction conversion member 838D, which isa plate-like member provided in parallel to a drop path of the plasticcase packed product P, is provided in the plastic case packed productdirection conversion portion 838C. The plastic case packed productdirection conversion member 838D slides laterally from the center of thechute portion 838A by an pneumatic-slider (air slider) not shown. By asetting signal from a control computer (not shown) for controlling thepackaging system 2000 set in accordance with a variety of the plasticcase packed products, the plastic case packed product directionconversion member 838D slides toward a predetermined position to controlthe direction of the plastic case packed product.

A plastic case packed product detecting portion 838E and a plastic casepacked product detecting portion 838F for detecting optically whether ornot the plastic case packed product P passes are provided at an inletand an outlet of the plastic case packed product direction conversionportion 838C. The plastic case packed product detecting portion 838E andthe plastic case packed product detecting portion 838F are connected tothe control computer. If the plastic case packed product detectingportion 838E and the plastic case packed product detecting portion 838Fdetect any plastic case packed product P, the control computer judgesthat the plastic case packed product P has passed through the plasticcase packed product direction conversion unit 838 normally and continuesthe operation of the plastic case packed product supplying unit 800. Onthe other hand, if the plastic case packed product detecting portion838F does not detect any plastic case packed product P although theplastic case packed product detecting portion 838E detects the plasticcase packed product P, the control computer judges that the plastic casepacked product direction conversion portion 838C is clogged with theplastic case packed product P and stops the operation of the plasticcase packed product supplying unit 800 and the winding machine 900.

The plastic case packed product P carried by the vertical conveyor 834is introduced into the chute portion 838A of the plastic case packedproduct direction conversion unit 838 in a condition that it is directedat right angle relative to the transporting direction. As indicated witha solid line in FIG. 58, the introduced plastic case packed product Pslips down through the chute portion 838A in the condition that it isdirected in the above-described direction. If the bottom portion strikesthe plastic case packed product direction conversion member 838D in theplastic case packed product direction conversion portion 838C, theplastic case packed product P is turned at 90° to a direction parallelto the falling direction as indicated with two-dot chain line in FIG. 58and introduced out to the second horizontal conveyor 836.

As shown in FIG. 57, the second horizontal conveyor 836 comprises a beltconveyor portion 836A for transporting the plastic case packed product Pand a guide plate 836B which are provided on both sides of the beltconveyor portion 836A and holds the plastic case packed product P fromfalling. The guide plate 836B located forward relative to this papersurface is omitted from FIG. 57.

(C) Winding Machine

The winding machine 900, as shown in FIGS. 59 and 60, includes a plasticcase packed product transporting line 916 for transporting themanufactured plastic case packed product P, an inspection portion 918for determining whether or not the manufactured plastic case packedproduct P is good by measuring its height and a plastic case packedproduct moving unit 920 for moving the plastic case packed product whichis determined to be a good product in the inspection portion 918 to anintake of the plastic case packed product introduction duct 831 at thesame time when the plastic case packed product P is moved from theplastic case packed product transporting line 916 to the inspectionportion 918.

The plastic case packed product moving unit 920 comprises an arm member922 having a V shaped plan shape, a plastic case packed product suctionportion 924A and a plastic case packed product suction portion 924B,which are provided on both ends of the arm member 922 for sucking theplastic case packed product P. The arm member 922 is fixed to a rotationshaft 926 provided vertically through a V-shaped bottom portion. Therotation shaft 926 is provided so as to be capable of expanding andcontracting and rotated by a drive means (not shown). If the rotationshaft 926 is expanded, the arm member 922 rises and if the arm member926 is contracted, the arm member 922 falls.

(D) Operation of First Plastic Case Packed Product Supplying Line

The plastic case packed product moving unit 920 carries a plastic casepacked product P determined to be acceptable by the inspection portion918 to an intake of the plastic case packed product introduction duct831 at the same time when the plastic case packed product P located atan end of the plastic case packed product transporting line 916 is movedto the inspection portion 918.

Specifically, as indicated with an arrow in FIG. 59, the arm member 922is rotated counterclockwise so as to locate both end portions of the armmember 922 over an end of the plastic case packed product transportingline 916 and the inspection portion 918. Next, the rotation shaft 926 iscontracted and the arm member 922 is fallen to the end of the plasticcase packed product transporting line 916 and a plastic case packedproduct located at the inspection portion 918. After the plastic casepacked product is determinated to be good by the inspection portion 918,the plastic case packed product P located at the end of the plastic casepacked product transporting line 916 is sucked at the plastic casepacked product suction portion 924A and the plastic case packed productP located on the inspection portion 918 is sucked by the plastic casepacked product suction portion 924B. After the plastic case packedproduct P is sucked, the rotation shaft 926 is expanded so as to raisethe arm member 922, so that as shown in FIG. 59, the plastic case packedproduct P is lifted up from the plastic case packed product transportingline 916 and the inspection portion 918. After the plastic case packedproduct P is lifted up, the rotation shaft 926 is rotated so as torotate the arm member 922 clockwise as indicated with an arrow in FIG.60. If both end portions of the arm member 922 are located above theinspection portion 918 and the plastic case packed product introductionduct 831, the rotation shaft 926 is contracted so as to descend theplastic case packed product suction portion 924A and the plastic casepacked product suction 924B. Then, the suctions of the plastic casepacked product suction portion 924A and the plastic case packed productsuction portion 924B are released, so that the plastic case packedproduct P sucked by the plastic case packed product suction portion 924Ais placed on the inspection portion 918 while the plastic case packedproduct P sucked by the plastic case packed product suction portion 924Bis fallen into the plastic case packed product introduction duct 831.

The plastic case packed product P fallen into the plastic case packedproduct introduction duct 831 is carried by the first horizontalconveyor 832 and abuts the stopper 832C and stops. The plastic casepacked product P which stops because it abuts the stopper 832C istransferred to the vertical conveyor 834 by the pusher 835 and broughtupward by the vertical conveyor 834. Then, that plastic case packedproduct P is turned at 900 by the plastic case packed product directionconversion unit 838, introduced into the second horizontal conveyor 836and then introduced into the plastic case packed product arrayingportion 810 by the second horizontal conveyor 836.

1-2 Plastic Case Packed Product Arraying Portion

As shown in FIGS. 54, 55, 61 and 62, the second horizontal conveyor 836and the second plastic case packed product supplying line 840 includedby the first plastic case packed product supplying line are providedsuch that they cross each other on the same horizontal plane. Theplastic case packed product arraying portion 810 is provided on theaforementioned intersection point and the plastic case packed productintroducing portion 820 is provided below it.

The plastic case packed product arraying portion 810 comprises a firstpusher 812 for supplying a plastic case packed product P supplied fromthe first plastic case packed product supplying line 830 to the plasticcase packed product introducing portion 820, a second pusher 813 forsupplying a plastic case packed product P′ supplied from the secondplastic case packed product supplying line 840 to the plastic casepacked product introducing portion 820, and a base 811 which holds thefirst pusher 812, the second pusher 813, an outlet portion of the secondhorizontal conveyor 836 and an outlet portion of the second plastic casepacked product supplying line 840 at predetermined positions.

The first pusher 812 is provided at an outlet of the second horizontalconveyor 836 and the second pusher 813 is provided at an outlet of thesecond plastic case packed product supplying line 840.

The base 811 comprises a base portion 811A extended in a L shape fromthe second pusher 813 to the first pusher 812 and a pusher supportingportion 811B which supports the outlet portions of the first pusher 812and the second horizontal conveyor 836. The base portion 811A isprovided with a plastic case packed product introduction opening portion811C for introducing the plastic case packed product P to the plasticcase packed product introducing portion 820. A portion between theplastic case packed product introduction opening portion 811C and thesecond horizontal conveyor 836 at the base portion 811A is formed in acircular shape along a trajectory of the first pusher member 812C, whichwill be described later, of the first pusher 812 and a guide wall 811Dfor holding the plastic case packed product P from dropping is providedon an outside edge. A guide wall 811E and a guide wall 811F are providedon both side edge portions between the second plastic case packedproduct supplying line 840 and the plastic case packed productintroduction opening portion 811C at the base portion 811A.

As shown in FIGS. 61 and 62, the first pusher 812 comprises an armmember 812B mounted at an end rotatably around a pivot 812A fixed on thepusher supporting portion 811B and a first pusher member 812C fixed onthe other end of the arm member 812B. The first pusher portion 812C isentirely formed in a planar crescent shape and extended in a directionleaving the plastic case packed product introduction opening portion811C. A cylindrical plastic case packed product stopper wall 812D formedaround the pivot 812A is provided on a circular edge portion of thefirst pusher member 812C. The plastic case packed product stopper wall812D is extended along the arm member 811B at an end portion on a sidefixed to the arm member 811B of the first pusher member 812C, forming aportion to be mounted to the arm member 811B. On the other hand, aplastic case packed product holding wall 812L parallel to the plasticcase packed product stopper wall 812D is fixed on an end portion on aside of the arm member 811B on which the first pusher 812C is fixed.

An actuator 812E for rotating the arm member 812B is mounted on theother end of the arm member 812B. The actuator 812E is mounted rotatablyon the pusher supporting portion 811B through the arm member 812H.Further, an automatic switch 812E2 detecting the rotating position ofthe arm member 812E is provided on the actuator 812E.

The pusher supporting portion 811B has rotation range setting screw 812Jand rotation range setting screw 812K for setting a rotation range ofthe arm member 812B.

When the arm member 812B is rotated by the actuator 812E, the firstpusher member 812C is moved on the base 811 while drawing a circulartrajectory so that it is located at a first position adjacent to an endof the second horizontal conveyor 836 or a second position adjacent tothe plastic case packed product introduction opening portion 811C. Inthe meantime, the first position in which the first pusher member 812Cis located is indicated with a solid line while the second position inwhich it is located is indicated with a two-dot chain line in FIG. 62.

At a portion of the second horizontal conveyor 836 below the firstpusher 812, a stopper 812N retaining plastic case packed products Pconveyed by the second horizontal conveyor 836 and a pneumatic slider812M popping the stopper 812N onto the second horizontal conveyor 836and retract it therefrom are provided.

Plastic case arrival detecting sensors 812F and 812G photo-electricallydetecting the arrival of plastic case packed products Pare providedadjacent to the stopper 812N in the upstream side therefrom so as tohave the second horizontal conveyor 836 between the two sensors 812F and812G.

The second pusher 813 has a second pusher member 813A for pushing theplastic case packed product P′. The second pusher member 813A isreciprocated on the base 811 by an air slider 813B in the direction atright angle to the second horizontal conveyor 836 and then, located at afirst position adjacent to an end of the second plastic case packedproduct supplying line 840 and a second position adjacent to the plasticcase packed product introduction opening portion 811C. In the meantime,the first position in which the second pusher 813A is located isindicated with a solid line and the second position is indicated with atwo-dot chain line in FIG. 61. On a portion of the second plastic casepacked product supplying line 840 downstream from the second pusher 813,a stopper 813C is disposed. The stopper 813C can be opened by anpneumatic slider.

The plastic case packed product P carried by the second horizontalconveyor 836 passes between the plastic case packed product stopper wall811D and the plastic case packed product holding wall 812L and isstopped by being retained by the stopper 812N. Then, the arrival of theplastic case packed product P is detected by the plastic case arrivaldetecting sensors 812F and 812G and a direction of the plastic casepacked product P is detected by a direction-detecting sensor (not shown)provided on the stopper 812N.

If the plastic case arrival detecting sensors 812F and 812G detect thearrival of the plastic case packed product P and the direction-detectingsensor provided on the stopper 812N detects that the plastic case packedproduct P is in a correct direction, the arm member 812B is rotated inthe direction indicated with an arrow in FIG. 62 and the first pushermember 812 is moved to the second position. Consequently, the plasticcase packed product P is pushed and dropped from the plastic case packedproduct introduction opening portion 811C to the plastic case packedproduct introducing portion 820.

After the plastic case packed product P drops on the plastic case packedproduct-introducing portion 820, the arm member 812B is rotated to anopposite direction to the aforementioned arrow, so that the first pushermember 812C is returned to the first position.

On the other hand, if the stopper 812N is opened, the plastic caseproduct P passes between the plastic case packed product stopper wall811D and the plastic case packed product holding wall 812L, moves into aproduct-collecting conveyor (not shown) located downstream from thesecond horizontal conveyor and discharged into a smaller silo (notshown).

While the first pusher 812 is moved from the first position to thesecond position and returned to the first position again, the plasticcase packed product P is carried by the second horizontal conveyor 836.However, because the outlet of the second horizontal conveyor 836 iscovered with the plastic case packed product stopper wall 812D if thefirst pusher 812 is not located at the first position, the plastic casepacked product P is stopped before the plastic case packed productarraying portion 810.

If the first pusher 812 is returned to the first position, a nextplastic case packed product P located most near the outlet on the secondhorizontal conveyor 836 is pushed out to the base 811. Then, the plasticcase packed product P is pushed by the first pusher member 812Caccording to the above-described procedure and dropped on the plasticcase packed product introduction opening portion 811C.

If a predetermined quantity of the plastic case packed products, forexample, three plastic case packed products P are supplied to theplastic case packed product introducing portion 820, a plastic casepacked product P′ is supplied to the plastic case packed productintroducing portion 820 by the second pusher 813.

The plastic case packed product P′ is carried to the plastic case packedproduct arraying portion 810 by the second plastic case packed productsupplying line 840 and abuts an end face of the second pusher member813A located at the first position and the guide wall 811F on the base811, and stopped.

After the plastic case packed product P′ is stopped at theaforementioned position, the second pusher member 813A is moved to thesecond position indicated with a two-dot chain line in FIG. 61.Consequently, the plastic case packed product P′ is pushed and droppedfrom the plastic case packed product introduction opening portion 811Cto the plastic case packed product introducing portion 820.

After the plastic case packed product P′ drops on the plastic casepacked product introducing portion 820, the second pusher member 813A isreturned to the first position.

While the second pusher member 813A is moved from the first position tothe second position and returned to the first position, the plastic casepacked product P′ is carried by the second plastic case packed productsupplying line 840. However, because the second pusher member 813Acovers the outlet of the second plastic case packed product supplyingline 840 when it is not located at the first position, the plastic casepacked product P′ is stopped before the plastic case packed productarraying portion 810.

The first pusher 812 and the second pusher 813 repeat theabove-described operation so as to supply the plastic case packedproduct P and plastic case packed product P′ to the plastic case packedproduct introducing portion 820 so as to obtain a predeterminedcombination.

1-3 Second Plastic Case Packed Product Supplying Line

As shown in FIGS. 54, 63 and 64, the second plastic case packed productsupplying line 840 comprises a lift-up conveyor 841 for grabbing theplastic case packed product P′ upward from the plastic case packedproduct silo 850, a vertical conveyor 842 for carrying the plastic casepacked product P′ grabbed upward by the lift-up conveyor 841substantially upward, a plastic case packed product arranging portion843 which is provided between the lift-up conveyor 841 and the verticalconveyor 842 for arranging the plastic case packed product P′ grabbedout by the lift-up conveyor 841 and supplying to the vertical conveyor842, a horizontal conveyor 845 for carrying the plastic case packedproduct P′ carried upward by the vertical conveyor 842 horizontally tothe plastic case packed product arranging portion 810, and a plasticcase packed product direction conversion unit 844 which is providedbetween the vertical conveyor 842 and the horizontal conveyor 845 forconverting the direction of the plastic case packed product P′ carriedby the vertical conveyor 842.

(A) Lift-Up Conveyor

The lift-up conveyor 841 is an elevating conveyor having a width capableof placing five or six plastic case packed products P′ horizontally andits bottom end portion is located near a bottom portion of the plasticcase packed product silo 850. It comprises a shelf plate 841A which isprovided horizontally and grabs the plastic case packed product P′ fromthe plastic case packed product silo 850 and a drive chain 841B on whichthe shelf plate 841A is fixed at a predetermined interval. As shown inFIGS. 65 and 66, the shelf plates 841A have a inverted U-shaped sectionand the adjacent two shelf plates 841A are fixed to the drive chain 841Bsuch that both of them abut each other without any gap when the drivechain 841B is expanded linearly. The drive chain 841B is held bysprockets 841C and 841D provided on both ends and rotate clockwise inFIG. 63.

As shown in FIGS. 63 and 65, a horizontal brush 841E is provided fromabove the plastic case packed product silo 850 toward the lift-upconveyor 841. The horizontal brush 841E comprises a brush base 841Ffixed within the plastic case packed product silo 850 horizontally and abrush fibers 841G stretched from the brush base 841F toward the lift-upconveyor 841. As shown in FIG. 65, the horizontal brush 841E has afunction of hitting down the plastic case packed product P′ placed suchthat it projects from the shelf plate 841A.

A vertical brush 841H is provided along a driving direction of thelift-up conveyor 841 below the horizontal brush 841E on an inner wall ofthe plastic case packed product silo 850. The vertical brush 841Hcomprises a brush base 841 i fixed in a driving direction of the lift-upconveyor 841 and brush fibers 841J stretched from the brush base portion841 i toward the central portion of the lift-up conveyor 841. Thevertical brush 841H has a function of hitting down the plastic casepacked product P′ placed on the shelf plate 841A such that it projectsfrom both ends thereof.

A portion of the lift-up conveyor 841 above the plastic case packedproduct silo 850 is covered with a cover 841K in order to prevent theplastic case packed product P′ grabbed from the plastic case packedproduct silo 850 from falling from the shelf plate 841A.

(B) Plastic Case Packed Product Arranging Portion

As shown in FIGS. 54, 63 and 66, a plastic case packed product arrangingportion 843 is provided at atop end of the lift-up conveyor 841.

As shown in FIGS. 63, 64, 66 to 69, the plastic case packed productarranging portion 843 comprises a plastic case packed productintroduction portion 843A, which is a chamber into which the plasticcase packed product P′ is introduced by the lift-up conveyor 841, aplastic case packed product direction conversion portion 843B locatedbelow the plastic case packed product introduction portion 843A and forconverting the direction of a plastic case packed product P′ introducedby the plastic case packed product introduction portion 843A such thatits lid is directed upward, a discharge conveyor 843C located below theplastic case packed product direction conversion arranging portion 843Band for pushing the plastic case packed product P′ whose direction isconverted by the plastic case packed product direction conversionarranging portion 843B out of the plastic case packed product directionconversion arranging portion 843B, an inclined chute 843D forintroducing the plastic case packed product P′ pushed by the dischargeconveyor 843C out of the plastic case packed product directionconversion arranging portion 843B, an arrangement transporting conveyor843E which is a horizontal conveyor located below the inclined chute843D and for moving the P packed product P′ to the vertical conveyor842, and a vertical duct 843F which is provided vertically from aterminal of the inclined chute 843D toward a beginning end of thearrangement transporting conveyor 843E and for introducing the plasticcase packed product P′ which slides down on the inclined chute 843D tothe arrangement transporting conveyor 843E.

The inclined chute 843D has side plates 843D2 disposed so that theplastic case packed product P′ can pass between them and a bottom plate843D4 disposed between the side plates 843D2 and form a bottom of theinclined chute 843D. The bottom of the plastic case packed product P′ issupported by the bottom plate 843D4. Thus, pendulous motion of theplastic case packed product P′ is prohibited and the plastic case packedproduct P′ smoothly slides down the inclined chute 843D.

A plastic case packed product stopper 843Y for holding the plastic casepacked product P′ which slides down on the inclined chute 843D at itsbottom end and introduces into the vertical duct 843F at a predeterminedtime interval is provided at a bottom end of the inclined chute 843D.The plastic case packed product stopper 843Y includes a roller 843Zwhich presses the plastic case packed product P′ from above and byrotating the roller 843Z at a predetermined time interval, the plasticcase packed product P′ is introduced into the vertical duct 843 at thepredetermined time interval.

As shown in FIG. 69, a pusher 843G for transferring the plastic casepacked product P′ carried by the arrangement transporting conveyor 843Eto the vertical conveyor 842 is provided at a terminal portion of thearrangement transporting conveyor 843E. The pusher 843G comprises aplate-like pusher plate 843H for pressing the plastic case packedproduct P′ carried by the arrangement transporting conveyor 843E towardthe vertical conveyor 842 and an air slider 843 i for reciprocating thepusher plate 843H along a direction at right angle to the arrangementtransporting conveyor 843E.

The plastic case packed product introduction portion 843A and theplastic case packed product direction conversion arranging portion 843Bare partitioned by a movable partition plate 843J. As shown in FIGS. 66and 67, the movable partition plate 843J is reciprocated by the airslider 843K in a direction approaching and leaving the lift-up conveyor841.

As shown in FIGS. 63, 64, 66 to 68, a pair of the plate-like arrangingplate 843L are provided half way of the plastic case packed productdirection conversion arranging portion 843B such that they are inparallel to each other and horizontal. An interval of the arrangingplates 843L is set to a size as large as allows a flange portion of thelid portion not to be passed through although the main body of theplastic case packed product P′ can pass.

A pair of the guide plates 843M are provided above the arranging plate843L and a pair of the guide plates 843N are provided below thearranging plate 843L. An interval between the guide plates 843M is setto a size as large as allows the plastic case packed product P′ to bepassed through and the an interval between the guide plates N is setsubstantially equal to the interval between the arranging plates 843L.

As shown in FIGS. 63, 64, 66 to 68, the discharge conveyor 843Ccomprises a drive belt 843P which is provided just below the arrangingplate 843L and the guide plate 843N and in parallel to the arrangingplate 843L, a pair of paddle portions 843Q, which are provided at rightangle to the drive belt 843P and at symmetrical positions to each other,a pair of pulleys 843R for holding and driving the drive belt 843P and adrive motor 843S for driving one of the pulleys 843R. The pulley 843R isheld by a pair of the holding plates 843T from outside. The arrangingplate 843L is fixed on the holding plate 843T through a arranging plateholding member 843U.

As shown in FIGS. 64 and 69, the arrangement transporting conveyor 843Ecomprises a belt conveyor portion 843V for transporting the plastic casepacked product P′ and a pair of guide plates 843W which are provided onboth sides of the belt conveyor portion 843V for holding the plasticcase packed product P from falling down. The guide plate 843W locatedforward relative to this paper in FIG. 64 is omitted. A stopper 843X forstopping the plastic case packed product P′ in the vicinity of thepusher 843G is provided at a terminal end of the arrangementtransporting conveyor 843E.

(C) Operation of Second Plastic Case Packed Product Supplying Line

Because in the lift-up conveyor 841, the drive chain 841B is rotatedclockwise in FIG. 63 as described above, the shelf plate 841A is movedupward within the plastic case packed product silo 850. Therefore, theplastic case packed product P′ accommodated in the plastic case packedproduct silo 850 is raised upward by the shelf plate 841A. Here, theplastic case packed product P′ placed on the shelf plate 841 such thatit is projected from an edge of the shelf plate 841A is hit downward bythe horizontal brush 841E and the vertical brush 841H as shown in FIG.65, and only the plastic case packed products P′ placed horizontally onthe shelf plate 841A are carried upward. When the plastic case packedproducts P are carried upward by the shelf plate 841A, the lid portionof some plastic case packed product P′ is directed to the right to thetransporting direction while that of others is directed to the left.

After the plastic case packed product P′ carried upward by the lift-upconveyor 841 is introduced into the plastic case packed productintroduction portion 843A, the movable partition plate 843J is moved sothat the plastic case packed product introduction portion 843Acommunicates with the plastic case packed product direction conversionarranging portion 843B as shown in FIG. 67A. Therefore, all the plasticcase packed products P′ introduced to the plastic case packed productintroduction portion 843A fall on the plastic case packed productdirection conversion arranging portion 843B. If the plastic case packedproduct P′ falls on the plastic case packed product direction conversionarranging portion 843B, the lid portion of the plastic case packedproduct P′ is hooked by the arranging plate 843L halfway of the fall, sothat the lid portion is held vertically in a condition that it is hookedby the arranging plate 843L as shown in FIG. 67B. Consequently, thedirection of the plastic case packed product P′ is arranged such thatthe lid portion is located up while its main body is located down.

Next, if the discharge conveyor 843C is rotated counterclockwise inFIGS. 64 and 68, the paddle portion 843Q of the discharge conveyor 843Cis moved to the left in FIGS. 64 and 68 between the arranging plates843L. Therefore, the plastic case packed product P′ held between thearranging plates 843L is introduced into the inclined chute 843D, inother words, discharged.

The plastic case packed product P′ introduced to the inclined chute 843Dslides down to a bottom end portion of the inclined chute 843D in acondition that its lid portion is directed upward and introduced to thevertical duct 843F at a predetermined interval by the plastic casepacked product stopper 843Y. Therefore, the plastic case packed productP′ is introduced into the vertical duct 843F in such a condition thatits main body reaches it earlier than its lid portion. Then, it isintroduced into the arrangement transporting conveyor 843E with thisposture. Therefore, as shown in FIGS. 64 and 69, the plastic case packedproduct P′ is carried by the arrangement transporting conveyor 843E in aposture that the main body faces the transporting direction.

The plastic case packed product P′ is carried by the arrangementtransporting conveyor 843E with the aforementioned posture and abuts thestopper 843X and stopped. Then, the plastic case packed product P′stopped by the stopper 843X is introduced to the vertical conveyor 842by the pusher 843G in a condition that its transporting direction ismaintained by the arrangement transporting conveyor 843E. Because thetransporting direction of the vertical conveyor 842 is at right angle tothe transporting direction of the arrangement transporting conveyor843E, the plastic case packed product P′ introduced to the verticalconveyor 842 is held horizontally and carried upward with its lidportion directed in a specific direction.

The plastic case packed product P′ lifted up by the vertical conveyor842 is turned in its direction by the plastic case packed productdirection conversion unit 844 and introduced into the horizontalconveyor 845 such that its axial direction is along the transportingdirection. Here, the plastic case packed product direction conversionunit 844 has the same structure as the plastic case packed productconversion unit 838 in the first plastic case packed product supplyingline 830. Therefore, in the plastic case packed product directionconversion unit 844, the plastic case packed product P′ introduced fromthe vertical conveyor 842 is introduced to the horizontal conveyor 845such that its main body is directed to the transporting direction andcarried to the plastic case packed product arraying portion 810.

1-4 Plastic Case Packed Product Supplying Portion

As shown in FIG. 70, the plastic case packed product introducing portion820 comprises a plastic case packed product chute 822 for transferringthe plastic case packed product P and the plastic case packed product P′(hereinafter referred to as plastic case packed product P(P′ )) arrangedby the plastic case packed product arraying portion 810 in apredetermined array downward, a nest portion 828 located above therotation table of the cartoner 400, a transporting conveyor 824 fortransporting the plastic case packed product P (P′) which falls throughthe plastic case packed product chute 822, and a transfer portion 826for transferring the plastic case packed product P (P′) carried by thetransporting conveyor 824 to the nest portion 828. The transportingconveyor 824 is provided with a direction detecting portion 827 fordetecting whether or not the plastic case packed product P(P′) is beingtransported in a condition that it is directed in a predetermineddirection, this detection portion being mounted adjacent to and abovethe transfer portion 826.

The plastic case packed product introducing portion 820 has a plate-likebase 821 erected vertically on a floor face and the plastic case packedproduct chute 822, the transporting conveyor 824, the transfer portion826 and the direction detecting portion 827 are fixed at predeterminedpositions on the base 821. The plastic case packed product chute 822,the transporting conveyor 824, the transfer portion 826, and thedirection detecting portion 827 correspond to the packaging object dropchute, the packaging object transporting means, the transfer means andthe direction detection means includes by the packaging object supplyingapparatus of the invention.

Respective components of the plastic case packed product introducingportion 820 will be described in detail as follows.

(A) Plastic Case Packed Product Chute

The plastic case packed product chute 822 has a zigzag-like path 822Ainclined at a gradient of 30° downward. The plastic case packed productintroduction opening portion 811C provided in the plastic case packedproduct arraying portion 810 communicates with an opening portion at atop end of the path 822A. The plastic case packed product P and plasticcase packed product P′ introduced from the plastic case packed productintroduction opening portion 811C are introduced into the path 822A fromthe top end opening portion and naturally drops onto the transportingconveyor 824 with a condition that it is loaded in the path 822A withoutany gap as shown in FIG. 70.

(B) Transportation Conveyor

The transporting conveyor 824 is a belt conveyor for transporting theplastic case packed product P and the plastic case packed product P′ bymeans of an iron rubber belt 824A. The iron rubber belt 824A haspartitions 824B provided at a specified interval, so that the plasticcase packed product P and the plastic case packed product P′ are heldbetween the adjacent two partitions. The iron rubber belt 824A is heldby three driven pulleys fixed on the base 821 and a drive pulley 824Ddriven by a motor M and rotated clockwise as indicated with an arrow inFIG. 70 so as to carry the plastic case packed product P and plasticcase packed product P′ which fall naturally on the path 822A of theplastic case packed product chute 822 to the transfer portion 826. Asupport plate 824E which supports the iron rubber belt 824A from down inorder to prevent it from being warped by a weight of the plastic casepacked product P(P′) is provided on a portion to be placed with theplastic case packed product P (P′) of the iron rubber belt 824A.

The guide plates 824F for guiding the plastic case packed product P(P′)from falling are provided on both sides of the transporting conveyor824. The guide plate 824E located in the closer side relative to thesurface of FIG. 70 is partially omitted in FIG. 70.

A transporting failure detecting portion 823 for detecting whether ornot the plastic case packed product P(P′) is being transported normallyby the iron rubber belt 824A is provided between the plastic case packedproduct chute 822 and the transporting conveyor 824. The guide plate824E located in the further side relative to the surface of FIG. 70 hasa cut out at a portion adjacent to the transporting failure detectingportion 823 so as not to interfere the motion of the transportingfailure detecting portion 823.

Additionally, as shown in FIG. 71, above the transporting conveyor 824and between the base 821 and the transporting failure detecting portion823, a plastic case packed product existence detecting sensor 825detecting whether a plastic case packed product P (P′) is between twoadjacent partitions 824B is disposed.

As shown in FIGS. 70 and 71, the transporting failure detecting portion823 comprises a first failure detecting portion 823A for detecting aplastic case packed product P (P′) floating from the iron rubber belt824A among plastic case packed products P (P′) transported by being heldbetween the partitions 824B and a second failure detecting portion 823Bfor detecting a plastic case packed product P(P′) exists between thepartitions 824B without a lid. FIG. 71A shows a front view of thetransporting failure detecting portion 823 and FIG. 71B shows a top viewthereof. The first failure detecting portion 823A and the second failuredetecting portion 823B correspond to the first transporting failuredetecting means and the second transporting failure detecting meansincluded by the packaging object supplying apparatus of the invention.

The first failure detecting portion 823A, as shown in FIG. 71A,comprises an arm member 823C one of which end is pivoted, a contactroller 823D provided rotatably at the other end of the arm member 823C,a spring 823E for urging the arm member 823C so as to rotate downward, astopper 823F for restricting a motion of the arm member 823C fromrotating downward and a detecting portion 823G for detecting the motionof the arm member 823C which tries to rotate upward. The contact roller823D corresponds to a contact element and the arm member 823C and thespring 823E correspond to contact element urging means and the detectingportion 823G corresponds to contact element motion detecting means.

As shown in FIGS. 71A, 71B and 71C, the second failure detecting portion823B comprises an arm member 823H one of which end is pivoted so as torotate in the directions approaching and parting from the base 821, acontact roller 823 i which is provided rotatably at the other end of thearm member 823H, a spring 823J for urging the arm member 823H so as torotate in the direction approaching the base 821, a stopper 823L forrestricting the motion of the arm member 823H's rotating in a directionapproaching the base 821 and a detecting portion 823M for detecting themotion of arm member 823H's rotation in the direction approaching thebase 821. A Supporting base 823N is horizontally disposed on the base821 and the arm member 823H is pivoted on the supporting base 823N by abearing 823K. The detecting portion 823M consists of a dog 823M2attached at the tip of the arm member 823H and a sensor 823M4 detectinga position of the dog 823M2. The contact roller 823 i corresponds to acontact element, the spring 823J and the arm member 823H correspond tocontact element urging means and the detecting portion 823M correspondsto contact element motion detecting means.

When the plastic case packed product P (P′) is being transportednormally on the transporting conveyor 824, in the first failuredetecting portion 823A, the arm member 823C urged in a directionrotating downward by the spring 823E is held at a position indicatedwith a solid line in FIG. 71A by the stopper 823F so as to prevent thecontact roller 823D from abutting on the plastic case packed product P(P′) being transported by the transporting conveyor 824. In the secondfailure detecting portion 823B, as indicated with a solid line in FIG.71B, the arm member 823H is rotated by the plastic case packed product P(P′) transported by the transporting conveyor 824 in a directionapproaching the base 821 resisting an urging force of the spring 823Jand abuts the stopper 823L.

If there takes place a transporting failure such that a plastic casepacked product P (P′) is transported with placing on two adjacentplastic case packed products P (P′) carried by the transporting conveyor824, as indicated with a two-dot chain line in FIG. 71A, or a plasticcase packed product P (P′) is floating from a correct location whiletransported by the transporting conveyor 824, the contact roller 823D ofthe first failure detecting portion 823A abuts the plastic case packedproduct P(P′) on the adjacent two plastic case packed products P(P′) orfloating from the correct location and is jumped upward. Thus, the armmember 823C also rotates upward. When this motion is detected by thedetecting portion 823F, the first failure detecting portion 823A detectsthe aforementioned transporting failure.

On the other hand, when no plastic case packed product P (P′) existsbetween the two adjacent partitions 824B of the transporting conveyor824 or a plastic case packed product P (P′) without a lid istransported, as indicated with a two-dot chain line in FIG. 71B, the armmember 823H is rotated by the urging force from the spring 823J in thedirection approaching the base 821 and touches the stopper 823L. Such amotion is detected by the detecting portion 823M and the second failuredetecting portion 823B detects the aforementioned transporting failureof the plastic case packed products.

If at least one of the first failure detecting portion 823A and thesecond failure detecting portion 823B detects any transporting failure,the transporting failure detecting portion 823 inputs a relating signalinto the control computer. If the aforementioned signal is inputted intothe control computer, the entire plastic case packed product supplyingunit 800 is stopped.

(C) Direction Detecting Portion

The direction detecting portion 827, as shown in FIGS. 72 to 76,comprises a direction determining dog 827A for determining which way theplastic case packed product P (P′) carried by the transporting conveyor824 is directed, a direction detecting portion base 827B which supportsthe direction determining dog 827A so as to be capable of advancing orretracting to the transporting conveyor 824, and a crank mechanism 827Cfor bring the direction determining dog 827A near or apart from thetransporting conveyor 824. The direction detecting portion base 827B isfixed on the base 821 through the supporting member 821A. The directiondetecting portion base 827B is provided with a pair of cylindrical guidemembers 827D for guiding the direction determining dog 827A in theaforementioned direction.

As shown in FIGS. 74 to 76, the direction determining dog 827A comprisesfive probe portions 827E disposed vertically, a base 827F which supportsthe probe portions 827E to the transporting conveyor 824 so as to becapable of advancing or retracting through a cylindrical bearing member827G and a dog position detecting sensor 827K for detecting the positionof the probe portion 827E. The bearing member 827G is fixed on a base827F.

The dog position detecting sensor 827K is comprised of a light shieldingelement 827 i and a light projecting/receiving element 827 J and thelight shielding element 827 i is fixed on a rear end portion of eachprobe portion 827E through a mounting plate 827H and the lightprojecting/receiving element 827J is fixed on the direction detectingbase 827B. The light projecting/receiving element 827 i comprises alight emission device and a light receiving device for receiving lightfrom the light emission device and the light emission device and thelight receiving device are provided at positions opposing each other.The light shielding element 827 i is a plate-like member entirely havinga U-like or inverted U like plan shape as shown in FIG. 76 while it'sfront end and rear end project to the light projecting/receiving element827J. FIG. 76 shows a top view of the direction determining dog 827A andits surrounding portion.

The direction determining dog 827A has a pair of guide rods 827L whichslides inside the guide member 827D for guiding the directiondetermining dog 827A in a direction approaching/leaving the transportingconveyor 824. An end of the guide rod 827L is fixed on the base 827F andthe other end is fixed on a plate-like guide rod fixing member 827M.

As shown in FIG. 76, the probe portion 827E comprises a shaft portion827E4 which slides inside one of the bearing members 827G and a cupportion 827E2 provided on a front end of the shaft portion 827E4. Amounting plate 827H is fixed on a rear end of the shaft portion 827E4.In the mounting plate 827H, a guide rod 827H′ is fixed in parallel tothe shaft portion 827E4. The guide rod 827H′ slides inside another oneof the bearing members 827G for guiding the probe portion 827E andpreventing the dog position detecting sensor 827K and the probe portion827E from rotating around the shaft portion 827E4. A coil spring 827E6for urging the cup portion 827E2 in a direction leaving the base 827F isinserted in between the cup portion 827E2 and the bearing member 827G.

The direction determining dog 827A is located at a position far from theplastic case packed product P (P′) at standby time as shown in FIGS. 74and 76A. Because at this time, the light projecting/receiving element827J is shielded by the light shielding element 827 i, no light from thelight emission device is detected by the light receiving device of thelight projecting/receiving element 827J.

When determining the direction of the plastic case packed product P(P′),the direction determining dog 827A is advanced toward the plastic casepacked product P(P′) being carried by the transporting conveyor 824 asshown in FIGS. 76B and 76C.

Because the light shielding element 827 i is advanced if the directiondetermining dog 827A is advanced, light from the light emission deviceis detected by the light receiving device in the lightprojecting/receiving element 827J. However, if the direction determiningdog 827A is advanced to its maximum extent, no light is detected becausethe light projecting/receiving element 827J is shielded by the lightshielding element 827 i again as shown in FIG. 76B.

Because a circular groove is provided in the lid of the plastic casepacked product P(P′), when the lid of the plastic case packed product P(P′) is directed to the direction determining dog 827A, a periphery ofthe cup portion 827E2 is engaged with the groove in the id of theplastic case packed product P(P′) if the direction determining dog 827Ais advanced as shown in FIG. 76B. Because at this time, the directiondetermining dog 827A is located at a position where it is advanced tothe maximum extent, the light projecting/receiving element 827J isshielded by the light shielding element 827 i so that no light isdetected.

On the other hand, when the bottom side of the plastic case packedproduct P(P′) is directed to the direction determining dog 827A, if thedirection determining dog 827A is advanced as shown in FIG. 76C, theperiphery of the cup portion 827E2 abuts the bottom of the plastic casepacked product P (P′), so that the direction determining dog 827A isstopped at a position where it is retracted from the position shown inFIG. 76B. Therefore, because the light projecting/receiving element 827Jis in a condition not shielded by the light shielding element 827 i,detection of light is carried out.

By advancing the direction determining dog 827A toward the transportingconveyor 824 in the direction detecting portion 827 and then checkingwhether or light detection is achieved in the light projecting/receivingelement 827J provided on each probe portion 827E, the direction of theplastic case packed product P(P′) can be determined.

If dragging occurs between the shaft portion 827E4 and the bearingmember 827G, when the direction determining dog 827A is retracted to themaximum extent as shown in FIG. 76D, the probe portion 827E is notadvanced by an urging force of the coil spring 827E6 but remains at theposition where it is retracted. Therefore, the lightprojecting/receiving element 827J is in a condition not shielded by thelight shielding element 827 i, so that light detection is carried out.

By retracting the direction determining dog 827A to the maximum extentafter the direction of the plastic case packed product P(P′) isdetermined and checking whether or not light detection is achieved inthe light projecting/receiving element 827J, it is possible to seewhether or not dragging occurs between the shaft portion 827E4 and thebearing member 827G.

(D) Transfer Portion and Nest Portion

As shown in FIGS. 70, 77 and 78, the transfer portion comprises a pairof bases 826A (upper and lower) provided at a position opposing the nestportion 828 and fixed on the base 821, a pair of sending sideopening/closing guides 826B provided at a front end of the base 826Asuch that it is capable of opening/closing, a plastic case packedproduct pusher 826C provided behind the sending side opening/closingguide 826B in the base 826A such that it is capable ofadvancing/retracting to/from the nest portion 828, and a guideopening/closing member 826D supported on the lower base 826A such thatit is capable of advancing/retracting to/from the nest portion 828 andfor opening/closing the sending side opening/closing guide 826B. FIG. 78shows a bottom view of the transfer portion 826 and to clarify themechanism in the base 826A, the base 826A is expressed with a two-dotchain line.

Two rotation shafts 826E for pivoting the sending side opening/closingguide 826B are provided vertically at a front end of the base 826A. Eachof the sending side opening/closing guide 826B is fixed to the rotationshaft 826E through the arm member 826F. Taper is provided on an outsideface at an end of a side on which the sending side opening/closing guide826B is fixed of the arm member 826F such that it narrows as it goestoward its front end. A coil spring 826G for urging the arm member 826Fin a direction opening the sending side opening/closing guide 826B isprovided at an end portion opposite to the side on which the sendingside opening/closing guide 826B is fixed of the arm member 826F. A guideopening/closing restriction member 826H which engages with the lowerbase 826A for restricting an opening size of the sending sideopening/closing guide 826B is fixed on a bottom end portion of therotation shaft 826E. The guide opening/closing member 826D, the armmember 826F and the coil spring 826G correspond to the guideopening/closing means.

The transfer portion 826 comprises a pusher advancing/retracting crank826 i for advancing/retracting the plastic case packed product pusher826C toward the nest portion 828 and a guide opening/closing memberadvancing/retracting crank 826J for advancing/retracting the guideopening/closing member 826D to/from the nest portion 828. A motion ofthe pusher advancing/retracting crank 826 i is transmitted to theplastic case packed product pusher 826C through a pair of the rods 826Land a linking rod 826K. Similarly, the motion of the guideopening/closing member advancing/retracting crank 826J is transmitted tothe guide opening/closing member 826D through the linking rod 826M. Inthe meantime, the rod 826L is guided by a cylindrical guide 826P fixedto a guide supporting member 826N provided vertically between upper andlower bases 826A in a direction advancing/retracting to/from a sendingside opening/closing guide 826B. A linking rod mounting member 826Q isfixed on a terminal of the rod 826L and the linking rod 826K is mountedrotatably on the linking rod mounting member 826Q. An end of the coilspring 826R for urging the plastic case packed product pusher 826C tothe nest portion 828 is fixed on the linking rod mounting member 826Q.

As shown in FIGS. 70, 71, 78, 79 and 80, the nest portion 828 comprisesa pair of receiving side opening/closing guides 828A provided on aperiphery of each of the upper table 400A and the lower table 400Blocated above the index table 404 on which a sack carton is to bemounted of the cartoner 400 such that they are capable ofopening/closing and a plastic case packed product chute 828F which islocated inside thereof and open to the transfer portion 826 with a Ushaped section. The plastic case packed product chute 828F functions asa guide for guiding the plastic case packed product P(P′) when theplastic case packed product is inserted into the sack carton loaded onthe index table 404.

The receiving side opening/closing guide 828A is pivoted by the rotationshaft 828B between the upper table 400A and the lower table 400B. Thereceiving side opening/closing guide 828A is fixed on the rotation shaft828B by the arm member 828C. A cam follower member 828D is fixed on abottom end portion of the rotation shaft 828B such that when the guideopening/closing member 826D included by the transfer portion 826advances to abut the cam follower member 828D, the same cam followermember 828D is opened outward to the transfer portion 826. A coil spring828E for urging the receiving side opening/closing guide 828A in aclosing direction is provided on each of an end on a side on which thereceiving side opening/closing guide 828A is fixed of the arm member828C and an end on its opposite side. FIGS. 79 and 80A show a top viewof the nest portion 828 and FIGS. 79 and 80B show a view of the nestportion 828 taken from the transfer portion 826.

As shown in FIGS. 79 and 80B, a pair of the opening/closing guides 828G,which are capable of opening/closing, are provided below the receivingside opening/closing guide 828A. The opening/closing guide 828G is urgedby a coil spring (not shown) upward, that is, in a closing direction andfunctions as a guide which when it is closed, forms a bottom of theplastic case packed product chute 828F and in which, when it is opened,a front end thereof abuts an inside wall of the sack carton and guides aplastic case packed product P (P′) which falls through the plastic casepacked product chute 828F, to the sack carton. Reference numeral 408 inFIGS. 79 and 80 denotes a plastic case packed product pusher which isvertically movable to load the plastic case packed product P (P′) intothe cartoner.

Because when the transfer portion 826 is in its standby condition, asshown in FIG. 81A, the guide opening/closing member 826D remainsretracted, the cylindrical cam member 826D2 provided at a front end ofthe guide opening/closing member 826D abuts an outside face of the armmember 826F form outside. Consequently, the arm member 826F rotates toinside resisting a urging force of the coil spring 826G so as to closethe sending side opening/closing guide 826B.

If with this condition, a predetermined quantity of the plastic casepacked products P(P′) are sent from the direction detecting portion 827above and introduced into the inside of the sending side opening/closingguide 826B, the guide opening/closing member 826D is advanced to thenest portion 828. Referring to FIG. 81, FIG. 81B shows a state in whicha front end of the guide opening/closing member 826D abuts the front endof the cam follower member 828D of the nest portion 828.

When the guide opening/closing member 826D is advanced, the arm member826F is opened outward by an urging force from the coil spring 826Gasshown in FIG. 81B. Because the guide opening/closing restriction member826H engages with the base 826A, the sending side opening/closing guide826B opens the arm member as large as the plastic case packed productP(P′) can pass and at the same time, the opening is restricted to suchan extent that a front end of the arm member 826F can make a contactwith the cylindrical cam member 826D.

When the guide opening/closing member 826D is advanced further from theposition shown in FIG. 81B, the cam follower member 828D is expandedfurther by the guide opening/closing member 826D at the nest portion 828as shown in FIG. 82A, so that the arm member 828C is opened outwardresisting an urging force of the coil spring 828E. Consequently, thereceiving side opening/closing guide 828A is opened outward.

When the receiving side opening/closing guide 828A is opened outward,the plastic case packed product pusher 828C is advanced to the nestportion 828 as shown in FIG. 82B, so that the plastic case packedproduct P(P′) inside the sending side opening/closing guide 826B istransferred to the inside of the plastic case packed product chute 828F.

If the plastic case packed product P (P′) is transferred to the nestportion 828, the guide opening/closing member 826D is retracted to aposition shown in FIG. 82A.

(E) Operation of the Plastic Case Packed Product Supplying Portion

The plastic case packed product P and plastic case packed product P′arrayed by the plastic case packed product arraying portion 810 in apredetermined array pass through the plastic case packed productintroduction opening portion 811C and are introduced into the path 822Afrom a top end opening portion of the plastic case packed product chute822 and finally drops to the transporting conveyor 824 in a conditionthe path 822A is filled there with without any gap as shown in FIG. 70.

The plastic case packed product P and plastic case packed product P′,after fall naturally from the plastic case packed product chute 822, aretransported to the direction detecting portion 827 by the transportingconveyor 824 in a condition in which they are loaded in every intervalbetween the partitions 824B of the transporting conveyor 824.

If the direction detecting portion 827 recognizes that the plastic casepacked product P and plastic case packed product P′ are arranged in apredetermined array order, for example, they forms a group of fourpieces arranged like “PPP′P”, they are transported to the transferportion 826 by the transporting conveyor 824. Here, “P” indicatesplastic case packed product P while “P′” indicates plastic case packedproduct P′.

Then, the group of the plastic case packed product P(P′) is transferredto the nest portion 828 at the transfer portion 826, it is loaded in thesack carton by the cartoner 400.

1-5 Operation of Entire System

The plastic case packed product P manufactured by the winding machine900 is transported to the plastic case packed product arraying portion810 by the first plastic case packed product supplying line 830. At thesame time, the plastic case packed product P′ accommodated in theplastic case packed product silo 850 is also transported to the plasticcase packed product arraying portion 810 by the second plastic casepacked product supplying line 840.

In the plastic case packed product arraying portion 810, the plasticcase packed product P from the winding machine 900 and plastic casepacked product P′ from the plastic case packed product silo 850 aretransported to the plastic case packed product introducing portion 820in a predetermined order, for example, in an array of four pieces like“PPPP′P”.

The plastic case packed product introducing portion 820 transfers theplastic case packed product P and plastic case packed product P′ to thecartoner 400 in a predetermined array. Therefore, in the cartoner 400,the plastic case packed product P and plastic case packed product P′ areinserted into the sack carton in an order of four piece of “PPP′P”.

In the plastic case packed product supplying unit of the fourthembodiment, as described above, the plastic case packed product Pmanufactured by the winding machine 900 and plastic case packed productP′ accommodated in the plastic case packed product silo 850 areautomatically combined in a predetermined array and supplied to thecartoner 400 and then packed in the sack carton.

A Fifth Embodiment

An example of the packaging system according to the invention will bedescribed below.

1. Configuration of Packaging System

The packaging system 2000 of the fifth embodiment, as shown in FIG. 83,comprises a winding machine 900, a plastic case packed producttransporting supplying unit 800, a cartoner 400, a carton arraying unit1100, a shrink packaging unit 1200, a corrugated board casing unit 1300,and a control computer 500. The winding machine 900 and the plastic casepacked product transporting supplying unit 800, the cartoner 400, thecarton arraying unit 1100 and the shrink packaging unit 1200, and thecorrugated board casing unit 1300 correspond to a packaging objectmanufacturing portion, a transporting supplying unit, a small boxpackage forming portion, an assembly forming portion and an exteriorpackaging forming portion in the packaging system according to theinvention. In the meantime, the carton arraying unit 1100, the shrinkpackaging unit 1200 and the corrugated board casing unit 1300 constitutea carton packing unit 1000.

The winding machine 900 manufactures a plastic case packed product Pwhich is an example of a case incorporated film of the invention bymaking perforations in a side edge portion of a long film according toan instruction from the control computer 500, cutting a photographicfilm having perforations to a predetermined length, winding thisphotographic film around a spool, accommodating the spool around whichthe photographic film is wound in a cartridge, and accommodating thecartridge in a plastic made film case.

The plastic case packed product transporting supplying unit 800 has afunction of supplying the plastic case packed products manufactured bythe winding machine 900 to the cartoner 400 in a condition in which theyare arranged in line. Additionally, it has a function of combining theplastic case packed product P manufactured by the winding machine 900with another plastic case packed product P having a different quantityof photographable frames or a different photographic film appropriately,arraying them in a predetermined pattern and supplying to the cartoner400. In any case, the plastic case packed product transporting supplyingunit 800 supplies the plastic case packed product P manufactured by thewinding machine 900 to the cartoner 400 without any deposit between thewinding machine 900 and the cartoner 400. Here, “without any depositbetween being manufactured and being packaged” means that a plastic casepacked product P manufactured ahead by the winding machine 900 is alwayssupplied to the cartoner 400 ahead of a plastic case packed productmanufactured after (first in and first out). In other words, the plasticcase packed product P is always supplied to the cartoner 400 in theirmanufacturing order.

The cartoner 400 manufactures a carton 700 by packing the plastic casepacked products manufactured by the winding machine 900 into a sackcarton.

In the carton arraying unit 1100, a predetermined quantity of thecartons 700 are arrayed in a predetermined form so as to form a cartonassembly 720. If the aforementioned carton 700 is a type which should besubjected to shrink packaging, the carton assembly 720 is carried on theshrink packaging unit 1200 and if the carton 700 is a type which is notsubjected to shrink packaging, the carton assembly 720 is transporteddirectly to the corrugated board casing unit 1300.

The shrink packaging unit 1200 is provided adjacent to the cartonarraying unit 1100 and has a function of forming a shrink-wrappedpackage 740 by shrink-packaging the carton assembly 720 transferred fromthe carton arraying unit 1100 and then transporting this to thecorrugated board casing unit 1300.

The corrugated board casing unit 1300 has a function of packing thecarton assembly 720 transported from the carton arraying unit 1100 orthe shrink-wrapped package 740 transported from the shrink packagingunit 1200 in a corrugated board box in a predetermined fashion. Here,the carton 700 corresponds to the small box package under the invention,the carton assembly 720 corresponds to the small box assembly under theinvention, and the shrink-wrapped package 740 corresponds to theshrink-wrapped package under the invention.

The control computer 500 has a function of controlling the cartonarraying unit 1100, the shrink packaging unit 1200, the corrugated boardcasing unit 1300, the cartoner 400, the plastic case packed producttransporting supplying unit 800 and the winding machine 900 according toa production plan inputted from the a host computer.

Hereinafter the carton arraying unit 1100, the shrink packaging unit1200, the corrugated board casing unit 1300, the cartoner 400, theplastic case packed product transporting supplying unit 800 and thewinding machine 900 will be described in detail.

1-1 Winding Machine

The winding machine 900, as shown in FIGS. 84 and 85, comprises a filmfeeding portion 902 for sending a photographic film F from a film roll Raround which the long photographic film F is wound, a perforatingportion 904 which makes perforations on both side edges of thephotographic film F fed by the film feeding portion 902, a side printportion 906 which bakes a latent image corresponding to a film type on aside edge of the photographic film F perforated by the perforatingportion 904, a cutting portion 908 for cutting the photographic filmhaving the latent image baked on the side edge to a predetermined lengthon a side print portion 906, a winding portion 910 for winding thephotographic film F cut to the predetermined length around a spool, acartridge loading portion 912 for loading the photographic film F woundaround the spool by the winding portion 910 into a cartridge and a casepacking portion 914 for loading the cartridge loaded with thephotographic film by the cartridge loading portion 912 into a plasticcase so as to produce the plastic case packed product P.

The film feeding portion 902 comprises a film roll portion 902A in whicha film roll R around which a long photographic film F is wound and afilm joining portion 902B for joining together a terminal of the fedfilm roll R with a front end of a new film roll R.

The perforating portion 904 comprises a die block 904A fixed below atransporting plane for transporting the photographic film and a punchblock 904B capable of rising/falling relative to the die block 904A. Anintermittent feeding roller 904C is disposed on the upstream side(hereinafter referred to as “upstream side”) and the downstream side(hereinafter referred to as “downstream side”) along the transportingdirection of the photographic film of each of the die block 904A and thepunch block 904B and a suction chamber 904D is disposed below the dieblock 904A.

The side print portion 906 comprises a constant velocity transportingroller 906C disposed on the upstream side, a first print portion 906Adisposed corresponding to the constant velocity transporting roller906C, a constant size transporting sprocket 906D disposed on thedownstream side relative to the constant velocity transporting roller906C and a second print portion 906B disposed corresponding to theconstant size transporting sprocket 906D.

The cutting portion 908 includes a movable blade 908A and a fixed blade908B disposed so as to oppose each other vertically across thetransporting path of the photographic film F. A nip roller 908C isdisposed in the downstream of the movable blade 908A and the fixed blade908B.

The winding portion 910 comprises a turn table 910A for winding thephotographic film F around a spool, a transfer turn table 910B adjacentto in the downstream the winding turn table 910A, a transfer unit 910Cprovided adjacent to in the downstream the transfer turn table 910B andfor transferring a spool around which the photographic film F is woundto the cartridge loading portion 912 and a pair of insert rollers 910E,910F located on the upstream side of the winding turn table 910A. Aguide plate 910K and an opening/closing guide plate 910L are providedbetween the pair of the insert rollers 910E and 910F, and between thepair of the insert rollers 910E and the winding turn table 910A.Further, a guide plate 910M is provided between the nip roller 908C andthe pair of insert rollers 910F.

The winding turn table 910A is a disc rotating clockwise in FIG. 85 andsix spool holding means 910D are provided on the periphery. A spoolsupplying station ST1, a spool positioning station ST2, a film endinsertion station ST3, a reserve winding station ST4, a winding stationST5 and a transfer station ST6 are provided in a clockwise directionaround the winding turn table 910A. A film guide 910G is provided belowthe reserve winding station ST4.

The transfer unit 910C comprises a horizontal arm member 910H rotatingvertically around a rotation axis and a spool holding portion 910Jprovided on both ends of the horizontal arm member 910H.

The cartridge loading portion 912 includes a disc like turn table 912Ain which cartridge holding portions 912B for holding a cartridge areformed at an equal interval on a periphery thereof.

In the winding machine 900, all its components except the case packingportion 914 are accommodated in a dark room so as to protect thephotographic film F from outside light.

In the winding machine 900, a film roll R around which a photographicfilm of a predetermined type, for example, ISO400 or ISO800 is wound isautomatically loaded on a film roll portion 902A of the film feedingportion 902. Then, the photographic film F is fed from the film roll Rat a predetermined velocity.

The photographic film F fed from the film feeding portion 902 is fedintermittently by an intermittent feeding roller 904C and pressedagainst the die block 904A by a suction force of the suction chamber904D. Therefore, the punch block 904B goes up and down relative to thedie block 904A, so that perforations are formed on both side edges ofthe photographic film at a specified interval.

The photographic film F, after the perforations are formed by theperforating portion 904, is sent to the side print portion 906. Then, abelt-like side print latent image is formed depending on its film typeon one or both side edge portions of the first print portion 906A andsuch latent images as a DX code, frame number figure, frame number code,product name are recorded depending on a film size of the photographicfilm F on the second print portion 906B.

On the other hand, in the spool supplying station ST1 of the windingportion 910, a spool is mounted on the spool holding means 910D of thewinding turn table 910A.

If the spool is mounted on the spool holding means 910D, the windingturn table 910A rotates by 60° clockwise and then, a preliminarypositioning of the spool is carried out by the spool positioning stationST2. Then, the winding turn table 910A rotates further by 60° clockwiseso as to send the spool to a film end insertion station ST3.

If the film end insertion station ST3 is sent to the spool, anopening/closing guide plate 910L is closed so as to form a film path forthe photographic film F to pass through and at the same time, the spoolis nipped at ST3, so that final positioning of the spool is carried outmechanically to prepare for insertion of the photographic film.

After the predetermined latent images are formed, the photographic filmF is sent to the film end insertion station ST3 by the nip roller 908C,a pair of the insert rollers 910E and a pair of the insert rollers 910F,then guided by the guide plate 910K, the opening/closing guide plate910L and the guide plate 910M through a specified path and an end of thephotographic film F is inserted into the spool located at the film endinsertion station ST3.

When the end of the photographic film F is inserted into the spool inthe film end insertion station ST3, the guide plate 910M is opened andthe photographic film F is fed by a specified length to the turn table910A by the nip roller 908C. Consequently, as shown in FIG. 85, a loopis formed between the nip roller 908C and a pair of the insert rollers910F. The photographic film is cut by the movable blade 908A and thefixed blade 908B in a condition that it is held by the nip roller 908C,a pair of the insert rollers 910F, a pair of the insert rollers 910E andthe guide plates 910K, 910L.

After the photographic film F is cut, the nip roller 908C, a pair of theinsert rollers 910F, a pair of the insert rollers 910E and the guideplates 910K, 910L are released and the winding turn table 910A rotatesfurther by 60° so as to carry the spool to the preliminary windingstation ST4. Then, the cut photographic film F is hung above the filmguide 910G.

The photographic film F is wound up to hallway in the preliminarywinding station ST4. If the photographic film is wound up to halfwaywithout any abnormality, the winding turn table 910A rotates further by60° and the spool moves to the winding station ST5. Then, it is wound onthe spool completely in the winding station ST5.

When the winding in the winding station ST5 is terminated, the windingturn table 910A rotates further by 60° so that the spool in which thephotographic film F is wound is moved to the transfer station ST6. Inthe transfer station ST6, it is transferred to the transfer turn table910B in a horizontal condition.

The transfer turn table 910B rotates counterclockwise in FIG. 85,changes the holding of the spool from its horizontal condition to thevertical condition while it rotates by 180° and transfers it to thetransfer unit 910C.

In the transfer unit 910C, the spool received from the transfer turntable 910B is moved to the cartridge loading portion 912 in a conditionthat it is held by the spool holding portion 910J.

In the cartridge loading portion 912, a half open cartridge is loaded inthe cartridge holding portion 912B. The spool transferred by thetransfer unit 910C is loaded into the half open cartridge in thecartridge holding portion 910B. A cartridge cap is loaded in a remainingopening portion of the half open cartridge in which the spool is loadedand then crimped so as to form a cartridge.

The cartridge formed in this way is placed on the transfer conveyor 912Cas indicated with an arrow in FIG. 85, transferred to the case packingportion 914 and packed in the P case main body in the case packingportion 914. Then, the P case cap is engaged in an opening portion at anend of the P case main body and then a plastic case packed product P iscompleted. The completed plastic case packed product P is introducedinto the plastic case packed product transporting supplying unit 800.

1-2 Plastic Case Packed Product Transporting Supplying Unit

The constitution and the operation of the plastic case packed producttransporting supplying unit 800 are the same as described in the fourthembodiment.

1-3 Cartoner

The cartoner 400 packages the plastic case packed products P (anddifferent type plastic case packed product P′) supplied from the plasticcase packed product transporting supplying unit 800 into the inside ofthe sack carton 710, which is a foldable box body having an openingportion and a flap portion forming a lid portion for covering theopening portion on each of both ends thereof as shown in FIG. 86.

As shown in FIGS. 86, the cartoner 400 comprises a carton supplying unit402, a rotation table 404 which rotates intermittently clockwise asindicated with an arrow a with the sack carton supplied from the cartonsupplying unit 402 on its outer peripheral portion, a carton openingforming portion 406 in which the sack carton 710 supplied from thecarton supplying unit 402 is constructed from its folding condition andmounted on the outer peripheral portion of the rotation table 404 suchthat an opening portion on a side having the header 704 is directeddownward and a part of a flap portion on the bottom is constructed so asto cover the opening on the bottom partially, a plastic case packedproduct loading portion 408 which is provided adjacent to the cartonopening forming portion 406 in the downstream (hereinafter referred toas “downstream”) along the rotation direction a and loads apredetermined quantity of the plastic case packed products, for example,four pieces from the upper opening portion with the lower opening of thesack carton 710 partially closed, an upper lid constructing portion 410which is provided adjacent to the plastic case packed product loadingportion 408 in the downstream and forms the upper lid by constructingthe remainder of the lower flap portion, a lower lid constructingportion 412 which is provided adjacent to the upper lid constructingportion 410 in the downstream and forms the lower lid for covering theupper opening portion of the sack carton 710 by constructing the upperflap portion and a carton discharging portion 414 which is providedadjacent to the lower lid constructing portion 412 in the downstream anddischarges out the sack carton 710 containing the loaded plastic casepacked products.

The carton supplying unit 402, the rotation table 404, the cartonopening forming portion 406, the plastic case packed product loadingportion 408, the upper lid constructing portion 410, the lower lidconstructing portion 412, and the carton discharging portion 414 are thesame as the carton supplying unit 2, the rotation table 4, the cartonopening forming portion 6, the plastic case-packed product packingportion 8, the upper lid constructing portion 10, the lower lidconstructing portion 12, and the carton discharging portion 14 of thecartoner relating to the fifth embodiment, respectively.

1-4 Carton Arraying Unit

As shown in FIGS. 83, 87 to 89, the carton arraying unit 1100 comprisesa first conveyor 1102 for feeding cartons dispatched from the cartoner400 one by one to a first robot 1112, a second conveyor 1104 disposed onthe downstream side din a carton 700 feeding direction (hereinafterreferred to as just “downstream side”) of the carton arraying unit 1100with respect to the first conveyor 1102, a third conveyor 1106 disposedon the downstream side of the second conveyor 1104, a fourth conveyor1108 disposed on the downstream side of the third conveyor 1106, a fifthconveyor 1110 disposed on the downstream side of the fourth conveyor1108 and extended to a product loading robot 1302, which will bedescribed later, of the corrugated board casing unit 1300, a first robot1112 disposed adjacent to a joint portion between the first conveyor1102 and the second conveyor 1104, a second robot 1114 disposed abovethe second conveyor 1104, and a third robot 1116 disposed above thethird conveyor 1106. The first conveyor 1102 to the fifth conveyor 1110correspond to transporting means in an assembly forming portion includedby the packaging system of the invention and the first robot 1112 andthe second robot 1114 correspond to rotating means included by theassembly forming portion. The second conveyor 1104 corresponds toassembling means included by the assembly forming portion. The thirdconveyor 1106 corresponds to the assembling means and an assemblytransporting means included by the assembly forming portion. The thirdrobot 1116 corresponds to the assembly transporting means.

1-4-A First Conveyor

As shown in FIGS. 87 to 91, the first conveyor 1102 comprises a beltconveyor 1102A, a frame body 1102B for holding the belt conveyor 1102Afrom both sides and a guide unit 1102C for guiding the frame body 1102Bvertically. FIG. 90A shows a top view of the first conveyor 1102 andFIG. 90B shows a front view thereof.

Because the cartoner 400 changes over the type of the plastic casepacked product with the top face of the carton 700 as a reference levelas shown in FIGS. 87 and 88, a lower conveyor 414A included by thecarton discharging portion 414 descends if the height of the carton 700is large and ascends if the height of the carton 700 is small in orderto make the height of the top face of the carton always constant.

The frame body 1102B of the first conveyor 1102 is mechanically joinedto the lower conveyor 414A so that it ascends or descends interlockinglywith the lower conveyor 414A. Then, the belt conveyor 1102A is held suchthat the top face thereof coincides with the top face of the lowerconveyor 414A.

Because the frame body 1102B goes up and down interlockingly with thelower conveyor 414A and the belt conveyor 1102A goes up and downaccompanied therewith, feeding of the carton 700 from the cartoner 400is carried out smoothly when the lower conveyor 414A is high or low.

The belt conveyor 1102A comprises a drive roller 1102E, four drivenrollers 1102F, and a belt 1102D wound around the drive roller 1102E andthe driven roller 1102F. The drive roller 1102E is driven by a drivemotor 1102G. Of the four driven rollers 1102F, two ones are located atend portions of the upstream side and downstream side of the beltconveyor 1102A while the remaining two ones are located near the driveroller 1102E. The belt 1102D is formed of material having a smallfriction coefficient. The carton 700 sent from the cartoner 400 isplaced on the top face of the belt conveyor 1102A.

The frame body 1102B comprises a frame plate 1102H located at a positionbackward relative to this paper in FIG. 90, that is, on a side opposingthe first robot 1112 as shown in FIG. 89, a frame plate 1102 i locatedon a side opposite to the first robot 1112 across the belt conveyor1102A, and a plate-like joining member 1102J for joining the frame plate11102H with the frame plate 1102 i. The drive roller 1102E and thedriven roller 1102F are pivoted by the frame plate 11102H in acantilever fashion.

As shown in FIGS. 90 and 91, the guide unit 1102C comprises a pair ofvertical guide rails 11102K extended vertically and a guide block 1102Lwhich engages with the vertical guide rail 11102K for guiding a framebody vertically. The guide block 102L is fixed on the frame plate11102H.

A guide plate 1102M having a C-shaped section is fixed on a top edge ofthe frame plate 1102H. On the other hand, a guide plate 1102N is erectedon a side opposite to the guide plate 1102M across the belt conveyor1102A. As shown in FIG. 91, a gap is formed between the guide plate1102N and the frame plate 102 i, so that a header 704 can pass throughwhen the carton 700 with the header 704 is transported.

As shown in FIG. 90, an air slide table 1102T for driving a cutterstopper 1102U and a cutter holder 1102S is fixed in a vertical guiderail 1102K of the frame plate 1102H.

The cutter stopper 1102U and the cutter holder 1102S are driven by theair slide table 1102T in a direction projecting or retracting over/fromthe belt conveyor 1102A through the guide plate 1102M.

The cutter stopper 1102U is located on the downstream side in thetransporting direction a (hereinafter referred to as “downstream side”)of the belt conveyor 1102A with respect to the cutter holder 1102S.

The cutter stopper 1102U has a function of stopping the carton 700 at aposition allowing a bar code attached to the carton 700 to be read by abar code reader 1102Q, which will be described later.

On the other hand, the cutter holder 1102S has a function of holding acarton located in the upstream to the carton 700 stopped by the cutterstopper 1102U to prevent it from moving to the downstream side incooperation with the guide plate 1102N.

A bar code reader 1102Q is provided at a position opposing the air slidetable 1102T across the belt conveyor 1102A and a metal detector 1102Pand a positioning sensor 1102R are provided on the downstream side ofthe bar code reader 1102Q.

The bar code reader 1102Q has a function of reading a bar code attachedto the carton 700 to detect for a mixture of a different type carton.

The metal detector 1102P has a function of detecting whether or not apredetermined quantity of the plastic case packed products are packed inthe carton 700.

1-4-B Second Conveyor

The second conveyor 1104 has a function of arraying the cartons 700,which are carried by the first conveyor 1102 and turned at 90° or 180°around the Y axis by the first robot, which will be described later soas to form a carton assembly 720 in which a predetermined quantity ofthe cartons 700 are arrayed in a predetermined style.

The second conveyor 1104, as shown in FIGS. 89, 92 and 93, comprises abelt conveyor unit 1104A, a supporting frame 1104B which comprises apair of frame plates provided so as to sandwich the belt conveyor unit1104A and a linking plate for linking these and supports the beltconveyor unit 1104A, and guide plates 1104C, 1104C′ provided on a topedge of the supporting frame 1104B and for guiding the carton 700 fromdropping from the belt conveyor unit 1104A. As shown in FIG. 89, theguide plate 1104C is located on a side opposite to the first robot 1112across the belt conveyor unit 1104A and the guide plate 1104C′ islocated on a side opposing the first robot 1112.

As shown in FIGS. 89 and 92, the belt conveyor unit 1104A comprises twobelt conveyors 1104A′ and 1104A″, which are adjacent to and parallel toeach other.

The belt conveyor 1104A′ and belt conveyor 1104A″ comprise belt 1104D′and belt 1104D″, drive roller 1104E′ for driving the drive roller 1104D′and drive roller 1104E″ for driving the belt 1104D″, and a driven roller1104F′ holding the belt 1104D′ and a driven roller 1104F″ holding thebelt 1104D″, respectively. The drive roller 1104E′ and the drive rollerE″ are driven by the drive motor 1104G. Because as shown in FIG. 93, thedrive roller 1104E′ has a larger outside diameter than the drive roller1104E″, the belt conveyor 1104A′ on a side far from the first robot 1112travels faster than the belt conveyor 1104A″ on a side near the firstrobot 1112. Therefore, when the carton 700 is being carried on the beltconveyor unit 1104A, it is turned to a direction to the first robot 1112when viewed from above. Therefore, even if the carton 700 has a header704, the header 704 of one carton 700 automatically overlap a main body702 of the carton 700, thereby forming a carton assembly 720, in whichthe cartons 700 make firm contact with each other.

The drive roller 1104E′ and drive roller 1104E″ and the driven roller1104F′ and driven roller 1104F″ are pivoted by a frame plate on a sideopposing the first robot 1112 of the frame plates which form the framebody 1104B.

An arraying portion 1104H for arraying the cartons 700 is formed on thedownstream side of the belt conveyor unit 1104A, that is, near the thirdconveyor 1106 and an introduction portion 1104 i for introducing thecarton 700 is formed near the upstream side of the arraying portion1104H.

As shown in FIGS. 92 to 94, a move guide plate 1104J is provided at aposition opposing the guide plate 1104C′ across the belt conveyor unit1104A of the arraying portion 1104H. The move guide plate 1104J is movedby an air slide table 1104K in directions of approaching an leaving thebelt conveyor unit 1104A. When the carton 700 is carried, the move guideplate 1104J is moved to the first position near the belt conveyor unit1104A as indicated with two-dot chain line in FIG. 94 so as to hold aside face of the carton 700 for the carton 700 not to drop from the beltconveyor unit 1104A. Then, when the cartons 700 are arrayed by thearraying portion 1104H, the move guide plate 1104J is moved to thesecond position far from the belt conveyor unit 1104A as indicated witha solid line in FIG. 94 so that it does not make an obstacle toarrangement of the cartons 700 on the belt conveyor unit 1104A.

As shown in FIGS. 92 and 95, a stopper 1104N having a L-shaped flatconfiguration is provided at an end in the downstream of the secondconveyor 1104. The stopper 1104N is moved along the width direction ofthe belt conveyor 1104A so as to project over and retract from atransporting plane of the belt conveyor unit 1104A by the air slidetable 1104P. The stopper 1104N has a function of pressing the cartons700 being carried on the transporting plane from the downstream side notto be moved to the third conveyor 1106 by projecting over thetransporting plane of the belt conveyor unit 1104A.

A pin 1104L is provided between the belt conveyor 1104A′ and the beltconveyor 1104A″ at a portion provided with the move guide plate 1104J ofthe belt conveyor unit 1104A. As shown in FIGS. 95 and 96, when fivepieces of the cartons 700, that is, so-called 1CD products, which arethe cartons 700 having the header 704 at one lid portion and contain asingle plastic case packed product each, are accumulated on the beltconveyor unit 1104A by the stopper 1104N, the pin 1104L is located belowthe fifth carton 700 if counted from the downstream side, so that it isprojected or retracted by the air slide table 1104T provided below thebelt conveyor unit 1104A. Consequently, the header 704 of the fifthcarton 700 does not overlap the main body 702 of the sixth carton 700.As a result, when the stopper 1104N is retracted, only the five cartons700 are transported to the downstream side, so that they are separatedfrom the sixth carton an cartons 700 located further in the upstream.

As shown in FIGS. 92 and 95, an auxiliary bar 1104U, which is horizontalrod-like member adjacent to the upstream side of the pin 1104L, isprojected at right angle to the belt conveyor unit 1104A from the moveguide plate 1104J to the belt conveyor unit 1104A. The auxiliary bar1104U is ascended or descended by the air slide table 1104M. As shown inFIGS. 19 and 20, the auxiliary bar 1104U rises with the pin 1104L so asto push up the header 704 of the fifth carton 700, helping the carton700 to override the pin 1104L.

The introduction portion 1104 i has a stopper plate 1104Q, which isprovided on the belt conveyor 1104A and capable of projecting/retractingalong the width direction of the belt conveyor unit 1104A. The guideplate 1104C has an opening portion which allows the stopper plate 1104Qto pass through. The stopper plate 1104Q is moved along theaforementioned direction by the air slide table 1104R.

As shown in FIG. 94, a header reception guide 1104S, which is located ata first position far from the belt conveyor unit 1104A or a secondposition near the belt conveyor unit 1104A, is provided below the guideplate 1104C. When a 2CD product, which is a carton 700 accommodating twopieces of the plastic case packed product for photographic film andhaving the header 704 at one lid portion thereof, is carried, the header704 is, as shown in FIG. 94, inserted into a gap between the beltconveyor unit 1104A and the guide plate 1104C and the 2CD product iscarried on the belt conveyor unit 1104A in its upside down state. Thus,the header reception guide 1104S takes the first position indicated witha solid line in FIG. 94 not to obstruct the transporting of the 2CDproduct. On the other hand, because when the 1CD product is carried, the1CD product is carried in a condition in which only one side edge of theheader 704 is inserted into the gap between the belt conveyor unit 1104Aand the guide plate 1104C, the header reception guide 1104S takes thesecond position indicated with a two-dot chain line in FIG. 94, in orderto prevent the 1CD product from falling down.

1-4-C Third Conveyor

The third conveyor 1106 has a function of sorting the carton assemblies720 formed by the second conveyor to ones which should be transported tothe shrink packaging unit 1200 and ones which should be transporteddirectly to the corrugated board casing unit 1300.

As shown in FIGS. 89 and 97, the third conveyor 1106 comprises a beltconveyor 1106A for carrying the carton 700 to the corrugated boardcasing unit 1300, a frame plate 1106B which supports the belt conveyor1106A and a guide plate 1106C erected so as to oppose the frame plate1106B across the belt conveyor 1106A. FIG. 97A shows a plan view of thethird belt conveyor 1106 when seen from above and FIG. 97B shows a frontview of an internal structure of the belt conveyor 1106A. The guideplate 1106C is omitted from FIG. 97B.

The belt conveyor 1104A comprises a drive roller 1106E, four drivenrollers 106F and a belt 1106D which is wound around the drive roller1106E and the driven roller 1106F. The drive roller 1106E is driven by adrive motor 1106G. The drive roller 1106E and the driven roller 1106Fare pivoted by the frame plate 1106B in a cantilever style. A drivemotor 1106G for driving the drive roller 1106E is fixed on a face on aside opposite to the side in which the drive roller 1106E and the drivenroller 1106F are pivoted of the frame plate 1106B.

A guide plate 1106H having a C-shaped section is fixed on a top face ofthe frame plate 1106B.

A carton arranging plate 1106 i is provided at an end portion on theupstream side of the third conveyor 1106, this carton arranging plate1106 i pressing the cartons 700 at right angle to the transportingdirection after introduced in a condition that they are arrayed by thearraying portion 1104H of the second conveyor 1104 in parallel to theguide plate 1106H across the belt conveyor 1106A so as to arrange thecartons in line. As shown in FIG. 97, the carton arranging plate 1106 iis capable of being moved in directions of approaching or leaving thebelt conveyor 1106A by the air slide table 1106J. As indicated with asolid line and a two-dot chain line in FIG. 97, the carton arrangingplate 1106 i takes the first position near the belt conveyor 1106A orthe second position far from the belt conveyor 1106A. The cartonarranging plate 1106 i arranges the introduced cartons 700 in line atthe first position.

An opening portion which allows two stoppers 1106K and 1106L to projectover the belt conveyor 1106A is provided at an end on the downstreamside of the carton arranging plate 1106 i.

The stoppers 1106K and 1106L have a function of holding any introducedcarton 700 from being pushed from the upstream side and moved to thedownstream side and are projected or retracted at right angle to themoving of the belt conveyor 1106A by the air slide table 1106M and theair slide table 1106N.

The guide plate 1106C is erected adjacent to the carton arranging plate1106 i and in the downstream thereof. The guide plate 1106C has aninverted L shaped section, so that a gap which allows the header 704 ofthe carton 700 to pass through is formed between the guide plate 1106Cand the belt conveyor 1106A.

1-4-D Fourth Conveyor

The fourth conveyor 1108 has a function for transporting the cartonassemblies 720 sorted to the ones which should be carried directly tothe corrugated board casing unit 1300 by the third conveyor 1106, to thefifth conveyor 1110.

1-4-E Fifth Conveyor

The fifth conveyor 1110 has a function of recognizing the quantity ofthe carton assemblies 720 transported by the fourth conveyor 1108 andarranging in line the carton assemblies 720 for the product loadingrobot loading robot 1302 of the corrugated board casing unit 1300.

FIG. 98A shows a plan view of the fifth conveyor 1110 taken from aboveand FIG. 98B shows a side view thereof taken from the side. The arrowindicates a transporting direction of the carton assembly 720.

As shown in FIG. 98, the fifth conveyor 1110 comprises a belt conveyor1110A, a carton arranging portion 1110B provided at an end on thedownstream side of the belt conveyor 1110A, and a carton detectingportion 1110C provided adjacent to the upstream side of the cartonarranging portion 1110B.

The belt conveyor 1110A comprises a belt 1110D, a driving roller 1110Efor driving the belt 1110D and a driven roller 110F for holding the belt1110D. The driving roller 1110E is driven by the drive motor 1110G.

A guide wall 1110H and a guide wall 1110 i are erected on both sides ofthe belt conveyor 1110A. The guide wall 1110H and the guide wall 1110 iare guides for preventing the carton assembly 720 carried by the beltconveyor 1110A from dropping from the belt 1110D. A gap is formedbetween the guide wall 1110H and the belt conveyor 1110A to allow theheader 704 to pass through when the carton 700 having the header 704 istransported. A pair of the carton pressing plates 1110J are provided onan end portion on a side in which the carton arranging portion 1110B isprovided of the belt conveyor 1110A instead of the guide wall 1110H andthe guide wall 1110 i such that they sandwich the belt conveyor 1110A.The carton pressing plate 1110J has a function of arranging the cartonassemblies 720 transported by the belt conveyor 1110A along the widthdirection by pressing from both sides and is capable of being moved byan air slide unit 1110K and an air slide unit 1110K′ provided so as tooppose each other across the belt conveyor 1110A along a direction atright angle to the transporting direction of the carton assembly 720. Atable 1110S for storing the carton assemblies 720 arranged by the cartonpressing plate 1110J temporarily is provided on the left side of thecarton pressing plate 1110J with respect to the advancement direction inFIG. 98.

The carton detecting portion 1110C comprises five light emissionportions 110L erected on a top edge of the guide wall 1110H along thetransporting direction of the carton 700, a carton detecting unit 1110Nwhich is provided on the upper edge of the guide wall 1110 i andconstituted of a light-receiving unit 1110M for receiving light fromeach light emission portion 1110L and a stopper plate 1110P providedadjacent to the downstream side of the carton detection unit 110N. Thestopper plate 1110P is moved by the air slide unit 1110Q in thedirection at right angle to the transporting direction of the cartonassembly 720, projected over the belt conveyor 1110A through a slit-likeopening portion formed in the guide wall 1110 i and then pulled outwardof the belt conveyor 1110A through the opening portion. A cartondetecting sensor 1110R for detecting whether or not a predeterminedquantity of the cartons, for example, five cartons exist in the cartondetecting portion 1110C photo-electrically is provided adjacent to thelight emission portion 1110L and light-receiving unit 1110M on thehighest upstream.

Adjacent the upstream side of the carton detecting sensor 1110R areprovided a carton holding unit 1110T capable of projecting/retractingthe belt conveyor 1110A and an air slide unit 110U for moving the cartonholding unit 1110T in the direction at right angle to the transportingdirection of the carton 700. The carton holding unit 1110T has afunction of holding the sixth carton if counted from the downstream sidenot so as to be carried to the downstream side in cooperation with theguide wall 1110H and introducing only a predetermined quantity, forexample, five cartons 700 into the carton arranging portion 1110B.

When the carton assemblies 720 sorted to the one which should betransported directly to the corrugated board casing unit 1300 on thethird conveyor 1106 are transported on the fourth conveyor 1108 and thefifth conveyor 1110, the stopper plate 1110P on the fifth conveyor 1110is ejected on the belt conveyor 1110A as indicated with a two-dot chainline in FIG. 98.

The carton assembly 720 carried by the fourth conveyor 1108 and thefifth conveyor 1110 abuts the stopper plate 1110P and is stopped at thecarton detecting unit 1110N. The carton detecting unit 1110N detectswhether or not the transported carton 700 is located properly in thevertical direction depending on which light from the light emissionportion 1110L is received by the light-receiving unit 1110M orinterrupted.

If the carton detecting sensor 1110R detects that the fifth carton 700is carried to the carton detecting unit 1110N, the stopper plate 1110Pis retracted as indicated with a solid line in FIG. 98. At the sametime, the carton holding unit 1110T is ejected on the belt conveyor1110A so as to hold the sixth carton 700 from being moved to the cartonarranging portion 1110B. Thus, only the five cartons constituting thecarton assembly 720 are transported to the carton arranging portion1110B.

The carton assembly 720 is pressed from both sides by the cartonpressing plate 1110J at the carton arranging portion 1110B so as toeliminate a disorder in the direction at right angle to the transportingdirection. At the same time, the carton assembly 720 is positioned. Whenthe carton assembly 720 is formed by stacking two carton groups eachcomposed of five cartons 700 vertically, after the first carton group iscarried to the carton arranging portion 1110B, that carton group issandwiched by the carton pressing plate 1110J and moved in the directionat right angle to the transporting direction and then placed on thetable 1110S so as to inhibit from obstructing an introduction of thesecond carton group to the carton arranging portion 1110B.

1-4-F First Robot

The first robot 1112, as shown in FIG. 99, comprises a suction/rotationportion 1112A which holds a carton 700 carried by the first conveyor1102 by sucking a side face thereof and rotates it by 90° or 180° aroundthe Y axis, a Z-axis guide portion 1112B for guiding thesuction/rotation portion 1112A in the direction of Z-axis and an X-axisguide portion 1112C for guiding the suction/rotation portion 1112A inthe direction of X-axis. As shown in FIG. 100, the X-axis is a rotationaxis along the transporting direction of the carton 700, the Y-axis is arotation axis within a horizontal plane along a direction at right angleto the Y-axis and the Z-axis is a rotation axis in a vertical direction,or in the height direction. The carton 700 shown in FIG. 100 is a 1CDproduct.

The suction/rotation portion 1112A comprises a suction portion 1112Ehaving a sucker 1112D for sucking and holding the side face of thecarton 700, and abase 1112F which holds the suction portion 1112E suchthat it is rotatable around the Y-axis with respect to its centralpoint.

The Z-axis guide portion 1112B comprises a guide rail 1112G erectedvertically and a guide block 1112H movable vertically in engagement withthe guide rail 1112G. The guide block 1112H is moved through a ballscrew provided vertically within the guide rail 1112G. Thesuction/rotation portion 1112A is fixed on the guide block 1112H.

The X-axis guide portion 1112C comprises a guide rail 1112 i provided inparallel to the first conveyor 1102, a traveling base 1112J whichtravels in the direction of the X-axis in engagement with the guide rail1112 i, and an air slide table 1112K which is fixed on the travelingbase 1112J for holding the guide rail 1112G on the Z-axis guide 1112B.The guide rail 1112G is held vertically by the air slide table 1112K andmoved in directions of approaching/leaving the first conveyor 1102 inthe direction of the Y-axis.

If the positioning sensor 1102R provided on the first conveyor 1102detects a carton 700, the Z-axis guide 1112B, the X-axis guide portion1112C and the air slide table 1112K are actuated, so that thesuction/rotation portion 1112A approaches the carton 700. The sucker1112D of the suction/rotation portion 1112A adheres to the side face ofthe carton 700 by suction. After the sucker 1112D adheres to the sideface of the carton 700 by suction, the base 1112E is rotated by 90° or180° or not rotated according to an instruction from the controlcomputer 500, moved in the height direction by the Z-axis guide 1112Band at the same time, moved by the X-axis guide portion 1112C along theX-axis. Consequently, the carton 700 is moved from the first conveyor1102 To the second conveyor 1104.

After the carton 700 is placed on the second conveyor 1104, thesuction/rotation portion 1112A is returned to its original position.

1-4-G Second Robot

The second robot 1114 has a function of rotating the carton 700transported by the first conveyor 1102 and the second conveyor 1104around the Z-axis.

The second robot 1114 is provided above the stopper plate 1104Q of thesecond conveyor 1104 as shown in FIGS. 89 and 101.

The second robot 1114 comprises a carton holding portion 1114A forsucking/holding the carton 700, a vertical-moving guide 1114B forguiding the carton holding portion 1114A vertically and a holding member1114C for holding the vertical-moving guide 1114B vertically.

The carton holding portion 1114A comprises a suction holding portion1114D for sucking/holding the carton 700, and a suction holding portionrotating motor 1114E which holds the suction holding portion 1114Drotatably around a rotation axis in the vertical direction.

The suction holding portion 1114D comprises a suction cup 1114F and aguide member 1114G for introducing the top of the carton 700 to thesuction cup 1114F.

A suction pipe 1114H is connected to the suction holding portionrotating motor 1114E. The suction pipe 1114H communicates with thesuction cup 1114F through a rotation shaft of the suction motor 1114E.

The vertical-moving guide 1114B comprises a guide rail 1114 i heldvertically by the holding member 1114C and a guide block 1114J whichmoves vertically in engagement with the guide rail 1114 i. The suctionholding portion rotating motor 1114E is fixed on the guide block 1114Jthrough a mounting metal 1114K.

After the stopper plate 1104Q is ejected over the belt conveyor unit1104A of the second conveyor 1104 and the carton 700 is stopped, thecarton holding portion 1114A descends to the carton 700, so that theguide member 1114G engages with the top of the carton 700. If a top faceof the carton 700 is sucked by the suction cup 1114F, the guide block1114J ascends along the guide rail 1114 i so that the carton 700 israised. Then, the suction holding portion 1114D is also rotated by 180°by the suction holding portion rotating motor 1114E. Consequently, thecarton 700 is rotated by 180° around the Z-axis. After the carton 700 isrotated by 180° around the Z-axis, the carton holding portion 1114Adescends, so that the carton 700 is placed on the belt conveyor unit1104A and then, depressurization of the suction cup 1114F is released.

1-4-H Third Robot

The third robot 1116 has a function of transporting the carton assembly720 formed by the second conveyor 1104 to the shrink packaging unit1200.

As shown in FIG. 89, the third robot 1116 comprises a chuck portion1116A which is provided adjacent to the shrink packaging unit 1200 andthe third conveyor 1106 and grips the carton assembly 720 formed byarraying the cartons 700 by the second conveyor 1104 and the thirdconveyor 1106 as shown in FIG. 102, a guide unit 1116B for moving thechuck portion 1116A in the directions of the Y-axis and Z-axis and acolumn 1116C for supporting the guide unit 1116B. A chuck rotation unit1116D for rotating the chuck portion 1116A around the X-axis is providedbetween the chuck portion 1116A and the guide unit 1116B.

As shown in FIG. 102, the guide unit 1116B comprises a Y-axis guide rail1116K which is fixed on the column 1116C and extended in the directionof the Y-axis, a Y-axis guide block 1116L, which engages with the Y-axisguide rail 1116K and slides on the Y-axis guide rail 1116K in thedirection of the Y-axis and a Z-axis guide rail 1116M, which is extendedvertically and movable vertically with respect to the Y-axis guide block1116L. The Y-axis guide block 1116L engages with the Z-axis guide rail1116M and the Z-axis guide rail 1116M has a ball screw shaft (not shown)which is extended in the longitudinal direction and engages with theY-axis guide block 1116L.

As shown in FIGS. 102 and 103, the chuck rotation unit 1116D is providedon a bottom end of the Z-axis guide rail 1116M.

The chuck portion 1116A comprises a pair of chuck pawls 1116E forchucking the carton 700, a chuck width setting unit 1116F for settingthe chuck width x of the chuck pawl 1116E and a pair of air slide units1116G for chucking the carton 700 by bringing the chuck pawls 1116E inwhich the chuck width x is set by the chuck width setting unit 1116Fnear each other.

Each of the chuck pawls 1116E is fixed on the air slide unit 1116G. Theair slide units 1116G are fixed symmetrically on a belt 1116H having thechuck width setting unit 1116F.

The carton positioning pawls 1116N are provided inside of the respectivechuck pawls 1116E such that they oppose each other. The cartonpositioning pawl 1116N is provided at right angle to the chuck pawl1116E and has a function of restricting the depth of gripping the cartonassembly 720 by the chuck pawl 1116E.

The belt 1116H is wound around a pair of belt wheels 1116 i and driven.Rack-like protrusions are provided on an inner peripheral face of thebelt 1116H. On the other hand, thread-like protrusions, which engage theprotrusions on the inner peripheral face of the belt 1116H, are providedon the outer peripheral face of the belt wheel 1116 i. One of the beltwheels 1116 i is rotated clockwise or counterclockwise by the motor1116P.

A guide rail 1116J for guiding the air slide unit 1116G along thetraveling direction of the belt 1116H is provided inside of the belt1116H.

The air slide unit 1116G comprises a guide block portion 1116G′ and aslide portion 1116G″ which slides on the guide block portion 1116G′ inparallel to the belt 1116H in engagement with the guide block portion1116G′. The guide block portion 1116G′ is fixed on the belt 1116H andslides on the guide rail 1116J in engagement with the guide rail 1116J.A pneumatic actuator (not shown) for moving the slide portion 1116G″with respect to the guide block portion 1116G′ is provided between theguide block portion 1116G′ and the slide portion 1116G″. Further, thechuck pawl 1116E is fixed on the slide portion 1116G″.

If the belt wheel 1116 i is rotated counterclockwise in FIG. 103, theair slide units 1116G are moved in directions of leaving each other.Thus, the chuck pawls 1116E are also moved in directions of leaving eachother as indicated with a solid line in FIG. 103, so that the chuckwidth x is enlarged. Conversely, if the belt wheel 1116 i is rotatedclockwise in FIG. 27, the air slide units 1116G are moved in directionsof approaching each other, so that the chuck pawls 1116E are also movedin directions of approaching each other as indicated with a two-dotchain line in FIG. 103 thereby reducing the chuck width x.

When the carton assembly 720 is gripped by the third robot, the Y-axisguide block 1116L slides on the Y-axis guide rail 1116K in the guideunit 1116B to adjust the position of the chuck portion 1116A so as to belocated above the carton assembly 720. At this time, the chuck pawl1116E is held such that it faces downward in the vertical direction asshown in FIG. 26.

If the chuck portion 1116A is located just above the carton assembly720, the Z-axis guide rail 1116M descends and therefore, the chuckportion 1116A also descends to the carton assembly 720.

If the carton positioning pawl 1116N included by the chuck portion 1116Aabuts the carton assembly 720, the Z-axis guide rail 1116M stopsdescending.

Next, the belt wheel 1116 i rotates clockwise so that the chuck pawls1116E approach each other so as to grip the carton assembly 720. If thecarton assembly 720 has the header 704, when it is gripped by the chuckpawls 1116E, the header 704 is located below and the carton positioningpawl 1116N makes a contact with a face opposite to a side containing theheader 704 of the carton assembly 720.

When the chuck pawls 1116E grip the carton assembly 720, the Z-axisguide rail 1116M ascends and correspondingly, the chuck portion 1116Aalso ascends.

Next, the chuck portion 1116A is rotated by the chuck rotation unit1116D around the X-axis to the left side in FIGS. 102 and 103, in otherwords, in the direction that the header of the gripped carton assembly720 is directed to the shrink packaging unit 1200, until the chuck pawl1116E is set horizontal.

If the chuck pawl 1116E is set horizontal, the Y-axis guide block 1116Lslides on the Y-axis guide rail 1116K so that the chuck portion 1116A ismoved upward of the shrink packaging unit 1200 along the Y-axis.

If the carton assembly 720 has no header 704 or the header 704 does notneed to be folded even if that header 704 is possessed, the chuckportion 1116A descends as it is so as to place the carton assembly 720on an introduction conveyor 1202A, which will be described later, of theshrink packaging unit 1200.

Of the carton 700 constituting the carton assembly 720 has the header704 while the header 704 needs to be folded, the chuck portion 1116A ismoved in the direction of the Y-axis and brings the header 704 into afirm contact with the guide plate 202B provided along the introductionconveyor 1202A of the shrink packaging unit 1200 shown in FIGS. 104 and105. Because the carton positioning pawl 1116N remains abutting on aface on a side opposite to the side provided with the header 704 of thecarton 720 when the carton assembly 720 is gripped by the gripping pawls1116E as described above, the header 704 is bent toward the main body702 of the carton 700 by a force of the chuck portion 1116A of pressingthe header 704 against the guide plate 202 b. After the header 704 isbent, the chuck portion 1116A places the carton assembly 720 on theintroduction conveyor 1202A.

1-5 Shrink-Packaging Unit

The shrink packaging unit 1200, as shown in FIGS. 104 and 105, comprisesan introduction portion 1202, a covering portion 1204, a heat-sealingportion 1206A shrink tunnel 1208, a height arranging portion 1210, anend arranging transportation unit 1212 and a mount supplying unit 1214.

The introduction portion 1202 comprises an introduction conveyor 1202Aon which the carton assembly 720 moved by the third robot 1116 is to beplaced in order to transport that placed carton assembly 720 to thecovering portion 1204 and a guide plate 202B provided along a side edgeon a side opposite to the side facing the third robot 1116 of theintroduction conveyor 1202A.

The covering portion 1204 contains a shrink film supplying portion 1216,which covers around the carton assembly 720 introduced by theintroduction conveyor 1202 with shrink film supplied from the shrinkfilm supplying portion 1216. A heat sealing portion 1206 heat-seals theshrink film along the periphery of the carton assembly 720 covered withthe shrink film by the covering portion 1204 and cuts. The cartonassembly 720, after the shrink film is heat-sealed by the heat sealingportion 1206, is heated in a shrink tunnel 1208 so that the shrink filmis contracted or tensed to form the shrink-wrapped package 740.

The height arranging portion 1210 arranges the shrink-wrapped packages740 formed in the shrink tunnel 1208 in line in the height direction. Anend arranging transporting unit 1212 arranges the end portions of theshrink-wrapped packages after an unevenness in the height direction isremoved by the height arranging portion 1210 in line and at the sametime, transports to the corrugated board casing unit 1300.

When the shrink-wrapped package 740 in which the carton 700 is placed ona mount thereof is formed, the mount is supplied to the introductionconveyor 1202 from a mount supplying unit 1214.

1-5-A Introduction Conveyor, Covering Portion, Heat-Sealing Portion,Shrink Portion and the Like

FIG. 105 shows the detail of the configuration of the introductionconveyor 1202, the covering portion 1204, the heat-sealing portion 1206,the shrink tunnel 1208, the mount supplying unit 1214 and the shrinkfilm supplying portion 1216.

The shrink film supplying portion 1216 supplies a shrink film to thecovering portion 1204 along a direction at right angle to thetransporting of the carton assembly 720 as shown in FIG. 105.

The shrink film supplying portion 1216 comprises an original roll 1216Awhich shrink film original twice-folded along the longitudinal directionis wound around, a pair of film placing rollers 1216B for supporting theoriginal roll 1216A from downward, a tension roller 1216C and a niproller 1216D which apply a tension to the shrink film S fed from theoriginal roll 1216A in the twice-folding condition and transport theshrink film S to the covering portion 1204, a film boring roller 1216Ewhich is comprised of four needle-like protrusions for boring airbleeding holes which allow inside air to escape at the time ofcontraction by heating, in the shrink film transported by the nip roller1216D, the needle-like holes being formed along the circumferentialdirection, and a pass roller 1216F and a pass roller 1216G which arelocated in the downstream of the film boring roller 1216E forintroducing the shrink film S to the covering portion 1204. The passroller 1216H is provided between the tension roller 1216C and the filmplacing roller 1216B. The pass roller 1216H applies a tension to theshrink film S and introduces the shrink film S so that a winding angleof the shrink film S to the tension roller 1216C is enlarged.

A disc-like perforation blade 1216 i for applying perforations to anupper shrink film of the shrink film S supplied in the twice-foldingcondition and a perforation receiving roller 1216J which opposes theperforation blade 1216 i across a transporting path for the shrink filmto be perforated are provided between the pass roller 1216G and thecovering portion 1204. A belt 1216K for transmitting a rotation force ofthe film boring roller 1216E to the perforation receiving roller 1216Jis provided between the perforation receiving roller 1216J and the filmboring roller 1216E.

The perforation blade 1216 i is a square cut blade which is driven androtated while pressed against the surface of the perforation receivingroller 1216J so as to press and cut the shrink film S.

The covering portion 1204 comprises a pair of triangular formers 1204Adisposed in parallel and above and below a product conveyor 1204B.

The triangular former 1204A is a right-angled isosceles triangularplate-like member. Of the shrink film S supplied from the shrink filmsupplying portion 1216 in the twice-folding condition, a half portionlocated up is wound around the upper triangular former 1204A while ahalf portion located down is wound around the lower triangular former1204A. The shrink film S is applied around the upper triangular former1204A such that it passes from its top face to its lower face throughits oblique side. On the other hand, the lower triangular former 1204Ais loaded with the shrink film S such that it passes from the lower faceto the upper face through the oblique side. Consequently, the shrinkfilm S is opened into a C-shape from the twice-folding condition andfurther, its traveling direction is converted to the same direction asthe transporting direction of the carton assembly 720 on the productconveyor 1204B.

The sealing portion 1206 comprises an L seal bar 1206A located above thetransporting path for the carton assembly 720, an L seal bar receiver1206B located below the L seal bar 1206A across the transporting pathfor the carton assembly 720, an L seal conveyor 206C disposed betweenthe L seal bar 1206A and the L seal bar receiver 1206B and film drivechains 1206D, 1206E provided adjacent to the L seal bar 1206A.

The L seal bar 1206A has a L-shaped flat configuration and seals alongthe periphery of the carton assembly 720 with the shrink film S and cutsinto a L shape in cooperation with the L seal bar receiver 1206B. Heatresistant rubber is bonded to a top face of the L seal bar receiver1206B.

The film drive chains 1206D, 1206E transport the shrink film S along thetransporting direction of the carton assembly 720 and the shrink film Son the L seal conveyor 1206C while nipping a side edge portion oppositeto a folded side of the shrink film S. The film drive chain 1206E isdriven by such an appropriate drive means as a motor and the film drivechain 1206D is driven following the film drive chain 1206E.

A shrink film take-up portion 1206F for taking up the remainder of theshrink film S left after the sealing by the L seal bar 1206A is providedadjacent to the film drive chain 1206E.

1-5-B Height Arranging Portion

FIG. 106 shows the detail of the configuration of the height arrangingportion 1210.

As shown in FIG. 106, the height arranging portion 1210 comprises apackage conveyor 1210A, a lid body 1210B which covers the packageconveyor 1210A from above, and an optical inspection portion 1210C whichis disposed between the package conveyor 1210A and the lid body 1210Bfor inspecting the shrink-wrapped package 740 placed on the packageconveyor 1210A.

The package conveyor 1210A is a belt conveyor on which theshrink-wrapped package 740 formed in the shrink tunnel 1208 is placedand mounted on a supporting base 1210D so that its top face coincideswith the same height as the transporting plane of the shrink-wrappedpackage 740 on the shrink tunnel 1208 and the end arranging transportingunit 1212. As indicated with a two-dot chain line in FIG. 106, thepackage conveyor 1210A is capable of rotating vertically along sideedges on a side provided with the product discharging chute 1210E of thesupporting base 1210D and on an opposite side.

The lid body 1210B includes a height arranging unit 1210H for arrangingthe heights of the shrink-wrapped packages 740 in line by pressing theshrink-wrapped packages 740 carried by the package conveyor 1210A fromabove.

The height arranging unit 1210H is located below the lid body 1210B andhas a rectangular flat configuration and comprises a pressing pad 1210 kfor pressing the shrink-wrapped package 740 directly, an air slide unit1210J for ascending/descending the pressing pad 1210 i with compressedair and a base 210K for fixing the air slide unit 1210J above the lidbody 1210B. The air slide unit 1210J is fixed on a fixing portion 1210J₂fixed on the base 210K and the pressing pad 1210 k and includes amovable portion 1210J₄ for sliding the fixing portion 1210J₂ vertically.The lid body 1210B contains a square opening portion through which themovable portion 1210J₄ passes.

When the shrink-wrapped package 740 is transported to below the lid body1210B by the package conveyor 1210A, the height arranging unit 1210Hdescends the pressing pad 1210 i toward the shrink-wrapped package 740and presses the top face of the shrink-wrapped package 740. Here,because the shrink-wrapped package 740 is heated by the shrink tunnel1208 so that it is plastic because it is just shrunk, an unevenness ofthe height existing just after the shrinking is removed when it ispressed by the pressing pad 1210 i.

The product discharge chute 1210E is provided on the forward side ofthis paper in FIG. 106 showing the supporting base 1210D and below thepackage conveyor 1210A. The product discharge chute 1210E discharges theshrink-wrapped package 740 out immediately so that no shrink-wrappedpackage 740 is left in the shrink tunnel 1208, when the shrink-wrappedpackage 740 is not carried smoothly because a trouble occurs in thedownstream of the height arranging portion 1210.

If any trouble occurs in the downstream, the package conveyor 1210A isrotated downward to the product discharge chute 1210E as indicated witha two-dot chain line in FIG. 106, so that the shrink-wrapped package 740on the package conveyor 1210A falls to the product discharge chute 1210Eand is discharged out.

Therefore, as long as the shrink-wrapped package 740 remains within theshrink tunnel 1208, if the shrink-wrapped package 740 is fed to thedownstream in the shrink tunnel 1208, the shrink-wrapped package 740 inthe shrink tunnel 1208 is discharged out through the product dischargechute 1210E.

The optical detection portion 1210C is a laser transmission typedisplacement sensor comprising a light projection device 1210F disposedon an outlet of the shrink-wrapped package 740 and a light receivingdevice 1210G disposed on a side opposite to the light projection device1210F across the package conveyor 1210A. The light projection device1210F emits laser beam and the light receiving device 1210G receives thelaser beam from the light projection device 1210F. The light projectiondevice 1210F and the light receiving device 1210G are disposed at thesame height as the shrink-wrapped package 740 and the carton 700 on thepackage conveyor 1210A so as to detect a deflection in the heightdirection of the shrink-wrapped package 740.

1-5-C End Arranging Transporting Unit

As shown in FIG. 107, the end arranging transporting unit 1212 comprisesa package conveyor 1212A, a package rotation portion 1212B located abovethe package conveyor 1212A and a transporting chute 1212C disposed inthe downstream of the package conveyor 1212A.

The package conveyor 1212A is a belt conveyor having the same width andheight as the package conveyor 1210A of the height arranging portion1210 and provided in a horizontal direction.

The package rotating portion 1212B comprises a package gripping portion1212D for gripping the shrink-wrapped package 740 and a lift-up anddown/turn actuator 1212E which lifts up and down the package grippingportion 1212D and at the same time, turns it every 90° around itsvertical rotation axis as indicated with a solid line and a two-dotchain line in FIG. 107.

The package gripping portion 1212D comprises a pair of plate-likeshrink-wrapped package gripping members 1212F for gripping theshrink-wrapped package 740, an actuator 1212G which holds theshrink-wrapped package gripping portions 1212F such that they opposeeach other and at the same time, moves them in directions ofapproaching/leaving each other, and a shrink-wrapped package grippingplate 1212H which is fixed on the actuator 1212G for holding theshrink-wrapped package 740, after carried by the package conveyor 1212A,at a position which allows the shrink-wrapped package gripping portions1212F to grip the same shrink-wrapped package 740. The rotation shaft ofthe lift-up and down/turn actuator 1212E is fixed on the actuator 1212G.

The transporting chute 1212C comprises a transporting conveyor 1212 ifor transporting the shrink-wrapped package 740 to the corrugated boardcasing unit 1300, a fall-down type drop chute 1212J for introducing theshrink-wrapped package 740 after transported by the package conveyor1212A to the transporting conveyor 1212 i, and a vertical guide 1212Kwhich is a vertical wall opposing the drop chute 1212J across thetransporting conveyor 1212 i. A stopper for stopping the shrink-wrappedpackage 740 is provided at an end in the transporting direction of thetransporting conveyor 1212 i. The stopper has a function of positioningthe shrink-wrapped package 740 in the transporting direction. Thevertical guide 1212K has a function of guiding the shrink-wrappedpackage 740 not so as to fall from the transporting conveyor 1212 i incooperation with the drop chute 1212J in a standup condition andpositioning the shrink-wrapped package in the direction at right angleto the transporting direction of the transporting conveyor 1212 i.

After the deflection in the height direction is removed by the heightarranging portion 1210, the shrink-wrapped package 740 is transported tothe end arranging transporting unit 1212 by the package conveyor 1210Aand then transported to the package rotating portion 1212B by thepackage conveyor 1212A and when it abuts the shrink-wrapped packagegripping plate 1212H, stopped between the shrink-wrapped packagegripping members 1212F.

If the shrink-wrapped package 740 should be turned at 90° beforetransported to the corrugated board casing unit, the actuator 1212G isactuated so that the shrink-wrapped package 740 is gripped on both sidesby the shrink-wrapped package gripping members 1212F. Consequently, thedeflection in the width direction of the shrink-wrapped package 740 isremoved.

Next, the package gripping portion 1212D is ascended by the lift-up anddown/turn actuator 1212E and the shrink-wrapped package 740 is departedfrom the package conveyor 1210A. Then, the package gripping portion1212D turns at 90° around a vertical rotation axis as indicated with atwo-dot chain line in FIG. 107 and then is placed on the packageconveyor 1212A.

If the shrink-wrapped package 740 is placed on the package conveyor1212A, the package gripping portion 1212D is ascended up to a positionwhich does not obstruct transporting of the shrink-wrapped package 740from being transported to the transporting chute 1212C.

At this time, the drop chute 1212J remains fallen against the packageconveyor 1212A as indicated with a solid line in FIG. 107, therebyforming a continuous plane connecting the package conveyor 1212A to thetransporting conveyor 1212 i. Thus, the shrink-wrapped package 740transported to the transporting chute 1212C drops to the transportingconveyor 1212 i through the drop chute 1212J.

After the shrink-wrapped package 740 drops on the transporting conveyor1212 i, the drop chute 1212J stands up as indicated with a two-dot chainline in FIG. 107 so as to place the shrink-wrapped package 740 on thetransporting conveyor 1212 i.

The shrink-wrapped package 740 placed on the transporting conveyor 1212i is transported to the product loading robot 1302 in the corrugatedboard casing unit 1300.

1-6 Corrugated Board Casing Unit

As shown in FIGS. 89 and 108, the corrugated board casing unit 1300comprises a box making machine 1306 for making a construction typecorrugated board box, a product loading robot 1302 for loading thecarton assemblies 720 and the shrink-wrapped package 740 into thecorrugated board box (hereinafter referred to as “empty corrugated boardbox 600” depending on a case) made by the box making machine 1306, acorrugated board box positioning portion 1304 which is provided adjacentto the product loading robot 1302 for holding the corrugated board box600 at a predetermined position, an empty corrugated board boxtransporting portion 1308 for transporting the empty corrugated boardbox 600 to the corrugated board box positioning portion 1304, aproduct-packed corrugated board box transporting portion 1312 fortransporting a corrugated board box (hereinafter referred to as “productpacked corrugated board box 600” depending on a case) loaded with theshrink-wrapped package 740 to a box sealing machine 1310, which will bedescribed next, the box sealing machine 1310 for sealing the productpacked corrugated board box 600 after transported by the product-packedcorrugated board box transporting portion 1312 and a storage conveyor314 for discharging out the product packed corrugated board box 600sealed by the box sealing machine 1310. The respective components willbe described in detail.

1-6-A Product Loading Robot

The product loading robot 1302 is a vertically multi-articular robot,which comprises, as shown in FIG. 109, a base 1302A placed on the base1302V, an arm portion 1302B rotatable with respect to the base 1302, anda hand portion 1302C which is provided at a front end of the arm portion1302B for gripping the carton assembly 720 or the shrink-wrapped package740.

The base 1302A is a vertically erected cylinder, which comprises a basemain body 1302D placed on the base 1302V and a horizontal cylindricalarm mounting portion 1302E located above the base main body 1302D. Thearm mounting portion 1302E incorporates a motor or actuator for rotatingthe arm portion 1302B.

The arm portion 1302B comprises a first arm 1302F mounted rotatably onthe arm mounting portion 1302E of the base 1302A, a second arm 1302Gmounted on a front end of the hand portion 1302C and an articulationportion 1302H for connecting the first arm 1302F and the second arm1302G through their end portions.

The first arm 1302F is mounted rotatably on the arm mounting portion1302E through an end thereof and rotated around a horizontal rotationaxis by a motor or an actuator in the arm mounting portion 1302E.

The articulation portion 1302H has three freedoms, which allow thesecond arm 1302G to rotate around three rotation axes comprised of ahorizontal rotation axis and two rotation axes intersecting thathorizontal rotation axis, those three rotation axes intersecting eachother. The articulation portion 1302H is provided at the other end ofthe first arm 1302 rotatably around a horizontal rotation axis andcomprises a first rotation portion 1302 i which rotates the second arm1302G in a vertical direction and a second rotation portion 1302J whichis provided at the first rotation portion 1302 i so as to be rotatablearound a rotation axis intersecting the aforementioned rotation shaftfor rotating the second arm 1302G in the right/left direction. Thesecond arm 1302G is provided on the second rotation portion 1302J so asto be rotatable around a center line of the second arm 1302G.

A work holding portion 1302K is provided at an end portion on a sideopposite to the side provided with the second rotating portion 1302J ofthe second arm 1302G such that it is rotatable around a rotation axis atright angle to the center line of the second arm 1302G. The work holdingportion 1302K comprises a work fixing shaft 302L in which the handportion 1302C is fixed on an end portion thereof and an arm mountingportion 1302M which is provided at the other end portion of the workfixing shaft 302L and held on the second arm 1302G rotatably. The workfixing shaft 302L is held rotatably by the arm mounting portion 1302M.

The hand portion 1302C, as shown in FIGS. 109 and 110, comprises a pairof finger-like members 1302N for gripping the carton assembly 720 or theshrink-wrapped package 740, a chuck width setting unit 1302P for settinga chuck width x of the finger-like member 1302N and a pair of air slideunits 302Q for bringing the finger-like members 1302N near/apart fromeach other after the chuck width x is set by the chuck width settingunit 1302P.

The chuck width setting unit 1302P comprises a belt 1302R havingrack-like protrusions on its inner peripheral face and a pair of beltwheels 1302S having thread-like protrusions engaging the aforementionedrack-like protrusions on its outer peripheral face. One of the beltwheels 1302S is rotated by a motor 1302T, so that the belt 1302R is alsorotated. The belt 1302R includes a guide rail 1302U for guiding the airslide unit 1302Q along the traveling direction of the belt 1302R.

The air slide units 302Q are fixed symmetrically on the belt 1302R.

The air slide unit 1302Q is fixed on the belt 1302R and comprises aguide block portion 1302Q₂ which engages the guide rail 1302U and aslide portion 1302Q₄ which slides on the guide block portion 1302Q₂ inparallel to the belt 1302R. A pneumatic actuator (not shown) is providedbetween the guide block portion 1302Q₂ and the slide portion 1302Q₄. Thefinger-like member 1302N is fixed on each slide portion 1302Q₄.

As shown in FIG. 111, the finger-like member 1302N is attached to theslide portion 1302Q₄ through the holding member 1302V. The holdingmember 1302V is a guide rail like member fixed on the slide portion1302Q₄. The finger-like member 1302N is engaged with the holding member1302V slidably in the vertical direction at its root thereof. Thefinger-like member 1302N is urged downward by a spring 1302W disposedbetween the holding member 1302V and the root of the finger-like member1302N.

An optical sensor 1302N₄ is provided at a front end of the finger-likemember 1302N. Further, an overload detecting sensor 1302N₄, which is anoptical sensor, is provided between the root of the finger-like member1302N and the holding member 1302V. The optical sensor 1302N₂ has afunction of detecting whether or not the carton assembly 720 or theshrink-wrapped package 740 is loaded in a corrugated board box 600,which will be described later, without any abnormality. The overloaddetecting sensor 1302N₂ has a function of detecting that an overload isapplied on the finger-like member 1302N by detecting that thefinger-like member 1302N is moved upward.

An operation of the product loading robot's loading of the cartonassembly 720 or the shrink-wrapped package 740 into the corrugated boardbox will be described below.

FIG. 112 shows the flow of the aforementioned operation in a flow chart.

As shown in FIG. 112, the product loading robot 1302 grips the cartonassembly 720 or the shrink-wrapped package 740 with its hand portion1302C in the same procedure as that explained in chuck portion 1116A onthe column “1-4-H Third robot” and then moves the hand portion 1302Cgripping the carton assembly 720 or the shrink-wrapped package 740 up tonear the corrugated board box 600. As shown in FIGS. 113A and 113B, theproduct loading robot 1302 descends the hand portion 1302C so that afront end of the finger-like member 1302N is located lower by a distanceD than a top face of the carton assembly 720 or the shrink-wrappedpackage 740. This distance D is so set up that the carton assembly 720or the shrink-wrapped package 740 is gripped securely by the handportion 1302 and that a force is not concentrated to a narrow range,depending on product type.

When the hand portion 1302C grips the carton assembly 720 or theshrink-wrapped package 740, the product loading robot 1302 moves thehand portion 1302C up to near the corrugated board box 6000 so as todetermine whether or not the carton assembly 720 or the shrink-wrappedpackage 740 is gripped properly.

When it is determined that the carton assembly 720 or the shrink-wrappedpackage 740 is gripped properly, the product loading robot 1302 proceedsto an operation of loading the carton assembly 720 or the shrink-wrappedpackage 740 into the corrugated board box 600.

On the other hand, when it is determined that the carton assembly 720 orthe shrink-wrapped package 740 is not gripped properly, the productloading robot 1302 determinates that an abnormality occurs and stops itsoperation and then outputs an abnormality occurrence signal to thecontrol computer 500.

When proceeding to the loading operation, the product loading robot 1302determinates whether or not a position where the carton assembly 720 orthe shrink-wrapped package 740 is loaded is at a final row of thecorrugated board box 600.

When the aforementioned insertion position is at the final row of thecorrugated board box 600, after the carton assembly 720 or theshrink-wrapped package 740 is loaded, as shown in FIG. 114B, the productloading robot 1302 moves the front end of the finger-like member 1302Nhorizontally along a flap portion folding position of the corrugatedboard box 600 so as to determine whether or not the optical sensor1302N₂ detects the carton assembly 720 or the shrink-wrapped package740.

If the optical sensor 1302N₂ detects nothing, it is determined that theloading into the entire corrugated board box is carried out properly andthen all the loading operation is terminated.

On the other hand, if the optical sensor 1302N₂ detects the cartonassembly 720 or the shrink-wrapped package 740, it is determined thatnot loaded carton assembly or shrink-wrapped package 740 rides on thecarton assembly 720 or the shrink-wrapped package 740 inserted in thecorrugated board box 600 and all the operation is stopped and at thesame time, the abnormality occurrence signal is output to the controlcomputer 500.

Unless the insertion position is at the final row of the corrugatedboard box 600, the product loading robot 1302 loads the carton assemblyor the shrink-wrapped package through the first or second action whilepreventing the hand portion 1302C, or the carton assembly 720 or theshrink-wrapped package 740 gripped by the hand portion from interferingwith the flap portions of the corrugated board box 600.

As the first action, the product loading robot 1302 loads the grippedcarton assembly 720 or shrink-wrapped package 740 while moving the handportion 1302C so as to stretch the flap portion. On the other hand, asthe second action, the hand portion 1302C is rotated so that the grippedcarton assembly 720 or shrink-wrapped package 740 is located on adiagonal line of an opening portion of the empty corrugated board box600 and then, the carton assembly 720 or the shrink-wrapped package 740is loaded.

Every time when a single loading is carried out, the finger-like member1302N is moved upward and pulled out from the corrugated board box 600.If the finger-like member 1302N reaches the flap portion foldingposition of the corrugated board box 600, it is stopped temporarily soas to detect whether or not the optical sensor 1302N₂ senses the cartonassembly 720 or the shrink-wrapped package 740.

If the optical sensor 1302N₂ does not detect any carton assembly 720 orshrink-wrapped package 740, it is determined that the carton assembly720 or the shrink-wrapped package 740 is loaded properly and the secondloading action begins.

On the other hand, when the optical sensor 1302N₂ detects the cartonassembly 720 or the shrink-wrapped package 740, it is determined thatthe loaded carton assembly 720 or shrink-wrapped package 740 is hookedand brought out of the corrugated board box 600 and all the action isstopped and then the abnormality occurrence signal is output to thecontrol computer 500.

Further, upon insertion, whether or not the optical sensor 1302N₄detects an upward motion of the finger-like member 1302N is determined.Here, if an end of the finger-like member 1302N or the carton assembly720 or the shrink-wrapped package 740 gripped by the finger-like member1302N abuts the carton assembly 720 or the shrink-wrapped package 740already loaded, the finger-like member 1302N is moved upward resistingthe urging force of the spring 1302W. Therefore, if the optical sensor1302N₄ senses the aforementioned motion, it can be determined that theaforementioned abutting is made.

If the optical sensor 1302N₄ senses the above-described motion, theproduct loading robot 1302 stops its loading operation, raises the handportion 1302C and stops it above the corrugated board box 600 so as tonotify an operation of an occurrence of that abnormality. After that,this system waits for confirmation and restoration by the operation.

1-6-B Empty Corrugated Board Transporting Portion

As shown in FIGS. 115 and 116, the empty corrugated board boxtransporting portion 1308 comprises a turn table 1308A for turning theempty corrugated board box 600 in the direction which facilitatesloading of the carton assembly 720 or the shrink-wrapped package 740 bymeans of the product loading robot 1302, a belt conveyor 1308B fortransporting the empty corrugated board box 600 made by the box makingmachine 1306 to the turn table 1308A and a roller conveyor 1308C fortransporting the empty corrugated board box 600 turned in apredetermined direction by the turn table 1308A to the corrugated boardbox positioning portion 1304.

The turn table 1308A comprises a conveyor portion 1308D on which theempty corrugated board box 600 is to be loaded and a base 1308 forholding the conveyor portion 1308D rotatably.

The conveyor portion 1308D comprises six rollers 1308F disposed inparallel to each other and a frame body 1308G for supporting the roller1308F rotatably around its axial line.

The frame body is a box whose top face is open and the roller 1308F isprovided in parallel to a short side of the frame body 1308G. Thus, anempty corrugated board box 600 placed on the conveyor portion 1308D istransported along the longitudinal direction of the frame body 1308G asindicated with an arrow in FIGS. 115 and 116.

A corrugated board box stopper 1308H is provided along one of the shortsides of the frame body 1308G which supports the empty corrugated boardbox 600 transported by the belt conveyor 1308B on the conveyor portion1308D. On the other short side of the frame body 1308G is fixed agangway plate 1308 i whose outer side is formed circularly while itsinner side is formed linearly.

The frame body 1308G is mounted rotatably on the base 1308E through acentral portion of its bottom face. If the frame body 1308A is rotatedon the base 1308E, the turn table 1308A takes the first position shownin FIG. 115 in which the gangway plate 1308 i is located on a side ofthe belt conveyor 1308B while the corrugated board box stopper 1308H isrotated so as to oppose the belt conveyor 1308B across the roller 1308For the second position as shown in FIG. 116 in which the gangway plate1308 i is located on a side of the roller conveyor 1308C.

The roller conveyor 1308C transports the empty corrugated board box 600in the direction at right angle to the transporting direction of theempty corrugated board box 600 on the belt conveyor 1308B and comprises,as shown in FIGS. 115 and 116, a group of rollers 1308J disposed in thedirection at right angle to the aforementioned transporting direction,frame bodies 308K, 308L for supporting the rollers 1308J rotatably and aguide rail 1308M fixed on a top edge of the frame body 1308L. Apositioning pusher 1308Q, which is a plate-like member in parallel tothe frame bodies 1308K, 1308L, is provided above the roller 1308J in thevicinity of the frame bodies 1308K, 1308L. The positioning pusher 1308Qis capable of moving in directions of approaching/departing from theguide rail 1308M on the roller conveyor 1308C and has a function ofdetermining the position in the width direction of the corrugated boardbox 600 on the roller conveyor 1308C as shown in FIG. 115.

A corrugated board pushing unit 1308N for pushing the empty corrugatedboard box 600 onto the roller conveyor 1308C is provided along the turntable 1308A and the roller conveyor 1308C. The corrugated board pushingunit 1308N is projected to the roller conveyor 1308C and comprises apushing rod 1308P for pushing out the empty corrugated board box 600 anda pushing rod guide 1308L which is extended in parallel to the framebody 1308K for moving the pushing rod 1308P in the transportingdirection of the roller conveyor 1308C.

An operation of the empty corrugated board box transporting portion 1308will be described below.

An empty corrugated board box 600 made by the box making machine 1306 istransported to the turn table 1308A by the belt conveyor 1308B. Becauseat this time, the turn table 1308A takes the first position as shown inFIG. 115, the corrugated board box carried by the belt conveyor 1308Babuts the corrugated board box stopper 1308H and is stopped on the turntable 1308A.

After the empty corrugated board box 600 is placed on the turn table1308A, the turn table 1308 rotates counterclockwise in FIG. 115 andtakes the second position as shown in FIG. 116.

When the turn table 1308A takes the second position, the pushing rod1308P pushes the empty corrugated board box 600 to the roller conveyor1308C as shown in FIG. 116. Consequently, the empty corrugated board box600 is placed on the roller conveyor 1308C. After the empty corrugatedboard box 600 is placed on the roller conveyor 1308C, the positioningpusher 1308Q moves to the guide rail 1308M so as to push the emptycorrugated board box 600 to the guide rail 1308M. As a result, theposition in the width direction of the corrugated board box 600 on theroller conveyor 1308C is determined. If the position in the widthdirection is determined, the corrugated board box 600 is transported tothe corrugated board box positioning portion 1304 on the roller conveyor1308C.

However, depending on the configuration and type of the empty corrugatedboard box 600, after it is made by the box making machine 1306 andtransported/placed to/on the turn table 1308A by the belt conveyor1308B, the empty corrugated board box may be transported to thecorrugated board box positioning portion 1304 by the roller conveyor1308C without being turned by the turn table 1308A.

1-6-C Corrugated Board Positioning Portion

As shown in FIGS. 89 and 117, a discharge conveyor 1312A for theproduct-packed corrugated board box transporting portion 1312, whichwill be described later, is provided at right angle to the rollerconveyor 1308C. Then, the corrugated board box positioning portion 1304is provided such that it is sandwiched by the discharge conveyor 1312Aand the roller conveyor 1308C.

The corrugated board box positioning portion 1304 is formed so as to becapable of inclining from its horizontal condition and comprises acorrugated board placing table 1304A which forms an end portion of theroller conveyor 1308C when it is set horizontal, as indicated with asolid line in FIG. 117, an inclination actuator 1304B for inclining thecorrugated board placing table 1304A, and a discharge unit 1304C fordischarging the product packed corrugated board box 600 in which thecarton assembly 720 or the shrink-wrapped package 740 is loaded on thecorrugated board placing table 1304A and discharging to the dischargeconveyor 1312A.

The corrugated board placing table 1304A comprises five rollers 1304Dprovided in parallel to the roller 1308J on the roller conveyor 1308Cand a pair of frame members 1304E, 1304F for supporting the roller 1304Drotatably. The frame member 1304E is located adjacent to the dischargeconveyor 1312A and the frame member 1304F is located on a side oppositeto the frame member 1304E across the roller 1304D. The corrugated boardplacing table 1304A is rotated around a bottom edge of the frame member1304F. Therefore, at the time of inclination, as indicated with atwo-dot chain line in FIG. 41, the side of the frame member 1304E israised by the inclination actuator 1304B.

An arrow in FIG. 117 indicates a transporting direction of the emptycorrugated board box 600 on the roller conveyor 1308C and the corrugatedboard placing table 1304A. Suckers 1304G, 1304H for sucking and holdingthe empty corrugated board box 600 are provided adjacent to an end offour rollers located at the second-fifth positions in the transportingdirection of five rollers 1304D. The sucker 1304G is fixed on the framemember 1304E adjacent to the second and fourth rollers 1304D along thetransporting direction, while the sucker 1304H is fixed on the framemember 1304F adjacent to the third and fifth rollers 1304D along thetransporting direction.

The discharge unit 1304C comprises a pressing plate 1304 i for pushingout the product packed corrugated board box 600 to the dischargeconveyor 1312A and a guide unit 1304J for transporting the pressingplate 1304 i along the width direction of the corrugated board placingtable 1304A. The guide unit 1304J comprises a guide rail 1304K extendedin the transporting direction of the empty corrugated board box 600 onthe corrugated board placing table 1304A, and a guide block 1304L whichslides on the guide rail 1304K in engagement with the guide rail 1304K.The pressing plate 1304 i is fixed on the guide block 1304L. Thepressing plate 1304 i is provided with a pair of the suckers 1304M forsucking and holding the empty corrugated board box 600.

The discharge unit 1304C is so constructed to be inclined integrallywith the corrugated board placing table 1304A as indicated with atwo-dot chain line in FIG. 117. The pressing plate 1304 i is located ata standby position above the frame body 1304F as indicated with a solidline when the empty corrugated board is loaded and guides the emptycorrugated board with the guide rail 1308M so as to form a guide railfor holding.

An operation of the corrugated board box positioning portion 1304 willbe described below.

Initially, the corrugated board placing table 1304A is set horizontal.Therefore, the empty corrugated board box 600, after transported by theroller conveyor 304C, abuts the guide block 1304L and is stopped on thecorrugated board placing table 1304A.

When the empty corrugated board box 600 is placed on the corrugatedboard placing table 1304A, the corrugated board placing table 1304A isinclined and the suckers 1304G, 1304H, 1304M suck the bottom face andside face of the empty corrugated board box 600 so as to fix the emptycorrugated board box 600 on the corrugated board placing table 1304A.

Next, the carton assembly 720 or the shrink-wrapped package 740 isloaded into the empty corrugated board box 600 by the product loadingrobot 1302.

After the loading of the carton assembly 720 or the shrink-wrappedpackage 740 is terminated, the corrugated board placing base 304A isreturned to a horizontal condition again, so that suction by the suckers1304G, 1304H, 1304M is released. Then, they are discharged to thedischarge conveyor 1312A by the discharge unit 1304C.

1-6-D Product Packed Corrugated Board Box Transporting Portion

As shown in FIG. 118, the product-packed corrugated board boxtransporting portion 1312 comprises a discharge conveyor 1312Aintersecting the roller conveyor 1308C and the corrugated board placingtable 1304A, a weight detecting unit 1312B provided adjacent to the boxsealing machine 1310 and a belt conveyor 1312C for introducing theproduct packed corrugated board box 600 discharged by the dischargeconveyor 1312A to the weight detecting unit 1312B.

The discharge conveyor 1312A is a roller conveyor.

The corrugated board pressing unit 1312D is provided adjacent to thedischarge conveyor 1312A and the belt conveyor 1312C and an ink jetprinter 1312E is provided adjacent to the corrugated board pressing unit1312D.

The corrugated board pressing unit 1312D comprises a guide rail 1312Fextended along an edge of the discharge conveyor 1312A, and a guideblock 1312G which slides on the guide rail 1312F in engagement with theguide rail 1312F as indicated with a two-dot chain line in FIG. 42. Theguide block 1312G is projected to the discharge conveyor 1312A andfunctions as a pushing member for pushing the product packed corrugatedboard box 600 to the belt conveyor 1312C.

A positioning plate 1312H, which is capable of projecting/retractingto/from the discharge conveyor 1312A for positioning the product packedcorrugated board box 600 discharged from the discharge conveyor 1312A onthe belt conveyor 1312C properly, is provided below the guide rail1312F. In FIG. 118, a condition in which the positioning plate 1312H isretracted is indicated with a solid line while a condition in which itis projected to the discharge conveyor 1312A is indicated with a two-dotchain line.

An operation of the product-packed corrugated board box transportingportion 1312 will be described below.

When a long side of the product packed corrugated board box 600 is atright angle to the discharge conveyor 1312A, while the dischargeconveyor 1312A transports the product packed corrugated board box 600,the guide block 1312G stands by outside the discharge conveyor 1312A asshown in FIG. 118. Then, if the product packed corrugated board box 600abuts the positioning plate 1312H, the guide block 1312G, after locatedat a position indicated with a solid line, slides on the guide rail1312F and moves to the belt conveyor 1312C, so that the product packedcorrugated board box 600 is pushed out to the belt conveyor 1312C.

On the other hand, if the long side of the product packed corrugatedboard box 600 is in parallel to the discharge conveyor 1312A, the guideblock 1312G moves onto a side edge on a side opposite to a side adjacentto the belt conveyor 1312C of the conveyor 1312A. If the product packedcorrugated board box 600 is transported on the discharge conveyor 1312Awith this condition, the guide block 1312G abuts an edge of the productpacked corrugated board box 600. Consequently, the product packedcorrugated board box 600 is rotated by 900 in the direction to the guiderail 1312F around the Z-axis as indicated with an arrow in FIG. 119, sothat its long side is at right angle to the discharge conveyor 1312A.After the product packed corrugated board box 600 is rotated until thelong side thereof is at right angle to the discharge conveyor 1312A, theproduct packed corrugated board box 600 is pushed out on the beltconveyor 1312C by the guide block 1312G like indicated in FIG. 42.

The product packed corrugated board box 600 pushed out to the beltconveyor 1312C is transported to the weight detection unit 1312B.

The weight detection unit 1312B detects whether or not the contentpacked in the product packed corrugated board box 600 is short.

The weight detection unit 1312B may determinates that the product packedcorrugated board box 600 is acceptable according to a fact that theweight of the product packed corrugated board box 600 is within apredetermined range.

However, if the quantity of types or the quantity of combinations istremendously large, a working load for determining a criterion value islarge. Even in case of the same type, if part lot changes to produce adifference in the weight of the product packed corrugated board box 600,so that a value serving as a criterion changes, a working load fordetermining the criterion value following that change is large also. Insuch a case, there is a method of determining that an product packedcorrugated board box 600 is acceptable if a difference between theweight of an product packed corrugated board box 600 and the weight ofan product packed corrugated board box 600 just before in a certain lotcontaining the same products is within a preliminarily set range betweenupper and lower limits. According to the above-described determinationmethod, if the range between the upper and lower limits is set up to besmaller than the weight of a single carton assembly 720 orshrink-wrapped package 740, an product packed corrugated board box 600having insufficiency of the quantity of the packaged carton assemblies720 or shrink-wrapped packages 740 can be removed as defective productsbecause such an product packed corrugated board box 600 is lighter thanthe lower limit. Further, even if different type product packedcorrugated board boxes 600 are fed through a production line, it is notnecessary to reset the weight criterion.

The product packed corrugated board box 60, after determined to beacceptable by the weight inspecting unit 312B, is transported to thesealing machine 1310.

1-7 Control Computer

As shown in FIG. 120, the control computer 500 comprises a cartoner PLC(Programmable Logic Controller) 502 for controlling the cartoner 400, acarton packing unit PLC 504 for controlling an entire carton packingunit 1000, a P-packed transporting supplying unit PLC 506 forcontrolling the plastic case packed product transporting supplying unit800, a shrink packaging unit PLC 508 for controlling the shrinkpackaging unit 1200 and a winding machine PLC 514 for controlling thewinding machine 900.

The control computer 500 comprises a process personal computer 510 forinputting an operation instruction to the cartoner PLC 502, a processpersonal computer 516 for inputting an operation instruction to thewinding machine PLC 514, and a host computer 512 for inputtingproduction plan to the process personal computer 510 and the processpersonal computer 516.

The cartoner PLC 502, the carton packing unit PLC 504, the plastic casepacked product transporting supplying unit PLC 506, the shrink packagingunit PLC 508 and the winding machine PLC 514 have a display fordisplaying condition setting instructions from the process personalcomputer 510 and the process personal computer 516 and a touch panel forinputting manufacturing condition.

If the production plan is inputted from the host computer 512 to theprocess personal computer 510 and the process personal computer 516, theprocess personal computer 510 inputs a condition setting instruction tothe cartoner PLC 502 and the process personal computer 516 inputs acondition setting instruction to the winding machine PLC 514.

The cartoner PLC 502 displays the condition setting instruction inputtedfrom the process personal computer 510 on a display.

If the cartoner PLC 502 displays the condition setting instruction onits display, an operator inputs various production condition through adisplay, a touch-up panel or a keyboard of the cartoner PLC 502.

The carton manufacturing/packaging condition which can be inputted tothe cartoner PLC 502 includes a condition about supply of the plasticcase packed product P, manufacturing of the carton 700, the cartonassembly 720 and shrink-wrapped package 740, a condition about loadingof the carton assembly 720 and the shrink-wrapped package 740 into thecorrugated board 600.

The condition about the supply of the plastic case packed product Pincludes, for example, the type of the plastic case packed product to besupplied to the cartoner 400, the quantity of the plastic case packedproducts P per a single supply, a combination of the plastic case packedproducts in case where multiple kinds thereof are supplied.

The condition about the production of the carton 700 includes aformation of the sack carton 710, the quantity of the plastic casepacked products which should be loaded in the sack carton 710, whetheror not a different type plastic case packed product should be loadedinto the sack carton and a combination of the plastic case packedproducts in case where different type plastic case packed products areloaded.

The condition about the carton assembly 720 and the shrink-wrappedpackage 740 includes the type, size and arrangement of the carton 700and whether or not shrink should be applied to the carton assembly 720.

The condition for loading the carton assembly 720 and the shrink-wrappedpackage 740 into the carton assembly 720 includes loading patterns ofthe carton assembly 720 and the shrink-wrapped package 740,configuration of the corrugated board 600 for use and the like.

If a working instruction is inputted to the process personal computer510, the process personal computer 510 inputs the condition settinginstruction into the cartoner PLC 502 based on the above-describedworking instruction.

The cartoner PLC 502 controls the cartoner 400 based on a manufacturingcondition of the carton 700 included in the inputted productioncondition. At the same time, the condition about the supply of theplastic case packed product is inputted to the plastic case packedproduct transporting supplying unit PLC 506. The condition about thecarton assembly 720 and the shrink-wrapped package 740 and the conditionabout loading of the carton assembly 720 and the shrink-wrapped package740 into the corrugated board 600 are inputted to the carton packingunit PLC 504. The plastic case packed product transporting supplyingunit PLC 506 controls the plastic case packed product transportingsupplying unit 800 based on the production condition inputted from thecartoner PLC 502. The carton packing unit PLC 504 controls the cartonarraying unit 1100 of the carton packing unit 1000 and the corrugatedboard casing unit 1300 based on the production condition inputted fromthe cartoner PLC 502 and at the same time, controls the shrink packagingunit 1200 through the shrink packaging unit PLC 508 if theaforementioned production condition contains an instruction formanufacturing the shrink-wrapped package 740 by shrink-packaging thecarton assembly 720.

By inputting the production condition into the cartoner PLC 502, unitsincluded in the plastic case packed product transporting supplying unit800, specifically, the plastic case packed product transportingsupplying unit 800, the cartoner 400, the carton arraying unit 1100, theshrink packaging unit 1200, and the corrugated board casing unit 1300can be set up about their conditions and controlled.

By inputting production conditions independently through the display,touch-up panel, and keyboard, the plastic case packed producttransporting supplying unit PLC 506, the carton packing unit PLC 504,and the shrink packaging unit PLC 508 can control the plastic casepacked product transporting supplying unit 800, the carton arraying unit1100, the corrugated board casing unit 1300, and the shrink packagingunit 1200 independently.

On the other hand, the winding machine PLC 514 displays a conditionsetting instruction inputted from the process personal computer 516 on adisplay like the cartoner PLC 502.

If the display of the winding machine PLC 514 displays the conditionsetting instruction, the operator inputs the plastic case packed productmanufacturing condition about the plastic case packed products throughthe display, touch-up panel and keyboard. The plastic case packedproduct manufacturing condition includes condition about sensitivity andnumber of frames, a spool for use, a single-side opening cartridge, acartridge cap, plastic case main body and plastic case. If theseconditions are inputted to the winding machine PLC 514, the windingmachine PLC 514 controls the winding machine 900 based on the inputtedmanufacturing condition.

Thus, if the production condition is inputted to the winding machine PLC514, that condition is set up in the winding machine 900, so that thewinding machine 900 is controlled independently of the plastic casepacked product transporting supplying unit 800 and other units.

2. Corrugated Board Box 2-1 Configuration of Corrugated Board Box

According to the invention, the corrugated board box for use in thecarton packing unit 1000 is classified to a corrugated board box havingthe partition and a corrugated board box having no partition.

FIGS. 121 and 122 show an example of the corrugated board box having thepartition and FIG. 123 shows a development diagram thereof.

As shown in FIGS. 121 to 123, the corrugated board box 600 comprises arectangular solid main body 602 whose top face is open, a partition 604for dividing the interior of the main body 602 to two sections and fourflap portions 606 provided on a top edge of the main body 602 forforming a lid portion for covering the opening portion when they arefolded.

The main body 602 comprises a bottom face 602C, a width-direction sideplate 602A which forms a side face in the width direction and alength-direction side plate 602B which forms a side face in thelongitudinal direction.

Inside flaps 606A, which are located inside when folded, of the fourflap portions 606 are provided on a top edge of the width direction sideplate 602A of the corrugated board main body 602 and outside flaps 606B,which are located outside when folded, are provided on the top edge ofthe length-direction side edge 602B.

The partition 604 is extended along the longitudinal direction of themain body 602 and fixed on one of the width-direction side plate 602A atits proximal portion 604A. A vertical cutout is made between thepartition 604 and the proximal portion 604A. Instead of providing with acutout at the root portion as shown in FIGS. 124 and 125, it ispermissible to provide with perforations in the vertical direction inFIGS. 124 and 125. The cutout or perforations at the root portion of thepartition functions a hinge.

An end portion on an opposite side to the root portion, which is an endportion on the side having the proximal portion 604A of the partition604, that is, a front end portion is not fixed on an inner wall face ofthe main body 602.

The height of the partition 604 is so set that a gap of 5 to 10 m isformed between the bottom and the lid of the corrugated board box 600when the lid is formed by folding the flap portions 606.

Therefore, the front end portion of the partition 604 is movable freelyalong the width direction inside the main body 602 as indicated withboth arrows in FIG. 122.

As shown in FIG. 123, bottom face flap portions 608A, 608B, which formthe bottom face 602C when folded, are provided on an opposite side tothe side provided with the flap portion 606 of the width-direction sideplate 602A and the length-direction side edge 602B.

FIG. 126 shows a procedure for loading such a shrink-wrapped package 740and a carton assembly 720 into the corrugated board box 600. FIGS. 50Ato 50H show the order of loading the product.

The corrugated board box 600 is partitioned to two rooms, a small room600A and a small room 600B along the length side thereof by thepartition 604.

As shown in FIG. 126B, an initial product is loaded to near the rootportion of the partition 604 in the small room 600A. The aforementionedproduct is loaded along the length-direction side plate 602B on the sidein which the small room 600A is formed as indicated with two-dot chainline in FIG. 126B and then, rotated to the width-direction side plate602A on the side in which the partition 604 is fixed as indicated with asolid line.

A second product is loaded on a side in which the proximal portion 604Aof the partition 604 in the small room 600B is located as shown in FIG.126C. The product is loaded along the length-direction side plate 602Bon the side in which the small room 600B is formed as indicated with atwo-dot chain line in FIG. 126C and then, rotated to the proximalportion 604A of the partition 604 as indicated with a solid line.

A third product is loaded to a position adjacent to the initial productin the small room 600A as indicated in FIG. 126D. The aforementionedproduct is loaded along the length-direction side plate 602B asindicated with a two-dot chain line in FIG. 126B and then, rotated to aposition adjacent to the initial product.

A fourth product is inserted into a position adjacent to the initialproduct in the small room 600B as indicated in FIG. 126E. Theaforementioned product is loaded along the length-direction side plate602B on the side in which the small room 600B is formed as indicatedwith a two-dot chain line in FIG. 126E, and next, rotated to the initialproduct as indicated with a solid line.

In this way, products are loaded into the small rooms 600A, 600Balternately and the partition 604 is fixed in the center of thecorrugated board box 600 by the loaded products.

When the final products are loaded into each of the small rooms 600A,600B, the final product is loaded into the small room 600A as indicatedin FIGS. 126F and 126G, and then the final product is loaded into thesmall room 600B as indicated in FIG. 126H.

Although an example in which the product is loaded into the small room600B after the product is loaded into the small room 600A first has beendescribed, conversely, it is permissible to load the product into thesmall room 600B and then load the product into the small room 600A.

3. Carton

A carton 700, which can be loaded into a corrugated board box by acarton boxing unit 1000, can accommodate 1 to 5 plastic case packedproducts.

Some carton 700 is composed of only a box-type main body 702 having noheader as shown in FIGS. 128 to 131, while some carton 702 has a header704 attached to the main body 704 as shown in FIGS. 132 to 139.

The carton 700 having the header 704 includes an example in which asshown in FIGS. 132 to 135, a header 704 having the same width as themain body 702 is provided on an end portion of the main body 702, anexample in which as shown in FIGS. 136 and 137, a header 704 having alarger width than the main body 702 is provided on an end portion of themain body 702, an example in which as shown in FIGS. 138 and 139, aheader 704 is provided along the side edge of the main body 702.

4. Operation 4-1 Procedure for Manufacturing of Plastic Case PackedProduct and Carton and Carton Packaging

FIG. 127 shows a flow of various products in the packaging system 2000.

If production plan is inputted to the process personal computers 510,516 from the host computer 512 as described about the control computer500, the process personal computer 510 and the process computer 516output the condition setting instruction to the winding machine 514.

After the operator inputs the plastic case packed product manufacturingcondition to the winding machine PLC 514, a film roll, spool,single-side opening cartridge, cartridge cap, plastic case and plasticcase cap are automatically supplied continuously to the winding machine900 according to the plastic case packed product manufacturing conditionand then, the plastic case packed products are produced.

On the other hand, if the operator inputs carton manufacturing/packagingcondition into the cartoner PLC 502, the plastic case packed producttransporting supplying unit 800, the cartoner 400, the carton arrayingunit 1100, the shrink packaging unit 1200 and the corrugated boardcasing unit 1300 are controlled according to the cartonmanufacturing/packaging condition, so that a process from loading theplastic case packed product into the sack carton 710 to loading of thecarton assembly 720 or the shrink-wrapped package 740 into thecorrugated board box 600 is controlled as a sequential process.

The winding machine 900 is controlled independently of the plastic casepacked product transporting supplying unit 800 and subsequent units.

When packaging of a plastic case packed product P₁, which is a type ofthe plastic case packed product, is terminated and packaging of aplastic case packed product P₂, which is a new type of the plastic casepacked product, is started, the manufacturing condition for the cartonerPLC 502 is maintained at a condition corresponding to the plastic casepacked product P₁ until a last product packed corrugated board box 600is discharged out of the corrugated board casing unit 1300.

After the last product packed corrugated board box 600 is discharged outof the corrugated board casing unit 1300, it is verified that nomaterial used for production and packaging of the plastic case packedproduct P₁ or no product is left in the sequential units of thepackaging system 2000 and if such material or product is left, it isremoved.

After it is verified that no material or product is left as a result ofthe above-described verification, a new condition about packaging of theplastic case packed product P₂ is inputted to the cartoner PLC 502 andnext, a new condition about manufacturing of the plastic case packedproduct P₂ is inputted to the winding machine PLC 514 and finally, themanufacturing and packaging of the plastic case packed product P₂ isstarted.

Instead of inputting the new manufacturing condition into the cartonerPLC 502 so as to execute the verification securely, it is permissible toset up new conditions for respective units included in the plastic casepacked product transporting supplying unit 800.

4-2 Carton Packaging Procedure

The procedures for arraying the carton 700 in the carton packing unit1000 included by the packaging system of the fifth embodiment so as toform the carton assembly 720 or the shrink-wrapped package 740 andpackaging into the corrugated board box will be exemplified.

4-2-A Boxing Procedure Example 1

The boxing procedure will be explained about the carton 700 shown inFIG. 136, which accommodates only a single plastic case packed productand has a header 704 having a larger width than the main body 702.

As shown in FIG. 140A, the carton 700 is discharged out of the cartoner400 with the header 704 facing downward.

If the carton arraying unit 1100 receives the control instruction, itrotates the carton 700, after transported by the first conveyor 1102Under a condition shown in FIG. 140A, by 90° such that the header 704 islocated on the upstream side relative to the transporting direction bythe first robot 1112 as shown in FIG. 140B.

The cartons 700, after rotated by 90°, are arrayed on the secondconveyor 1104 Such that the header 704 overlaps the main body 702 asshown in FIGS. 140C and 140D so as to form a carton assembly 720composed of five cartons 700.

The carton assemblies 720 formed by the second conveyor 1104 aretransported to the third conveyor 1106 and arrayed there. As shown inFIG. 140D, the carton assembly 720 is gripped with the chuck pawls 1116Eincluded by the third robot 1116 from both sides and brought up andthen, rotated such that the header is set horizontal and finally, thecarton assembly 720 is transported onto the introduction conveyor 1202in the shrink packaging unit 1200. Because a mount is already suppliedto the introduction conveyor 1202 from the mount supplying unit 1214according to an instruction from the control computer 500, the cartonassembly 720 is descended to the introduction conveyor 1202 by the thirdrobot 1116 and placed on the mount as shown in FIG. 140F.

After placed on the mount, the carton assembly is introduced to thecovering portion 1204 by the introduction conveyor 1202 and covered withshrink film from both faces. After that, the carton assembly passesthrough the heat sealing portion 1206 And the shrink tunnel 1208, sothat as shown in FIG. 140G, shrink packaging is performed so as to formthe shrink-wrapped package 740.

The shrink-wrapped package 740 is inspected by the height arrangingportion 1210 and their ends are arranged in line by the end arrangingtransporting unit 1212. Then, they are transported to the corrugatedboard box positioning portion 1304 of the corrugated board casing unit1300 by the transporting conveyor 1212 i.

In the corrugated board box positioning portion 1304, the shrink-wrappedpackage 740 is loaded in the empty corrugated board box 600 by theproduct loading robot 1302 according to the procedure shown in FIG. 126.

4-2-B Boxing Procedure 2

The procedure for arraying the carton 700 shown in FIG. 133, whichaccommodates three plastic case packed products and has the header 704having the same width as that of the main body 702 will be explainedbelow.

As shown in FIG. 141A, the carton 700 is discharged from the cartoner400 with the header 704 facing downward and transported by the firstconveyor 1102 of the carton arraying unit 1100.

The carton arraying unit 1100 transports the carton 700 aftertransported by the first conveyor 1102 To the second conveyor 1104without turning it in the first robot 1112.

The second conveyor 1104 forms the carton assembly 720 by arraying fivepieces of the cartons 700 after transported by the first conveyor 1102,as shown in FIG. 141B.

The carton assembly 720 formed by the second conveyor 1104 istransported to the third conveyor 1106 and arrayed there. As shown inFIG. 141C, the carton assembly 720 is gripped with the chuck pawls 1116Eof the third robot 1116 and brought up with the header 704 facingdownward.

Next, as shown in FIG. 141D, in the third robot 1116, the chuck rotationunit 1116D is rotated so as to rotate the chuck portion 1116A until thechuck pawl 1116E is set horizontal. Then, the chuck portion 1116A iscarried to just above the introduction conveyor 1202 of the shrinkpackaging unit 1200 by the guide unit 1116B. The chuck portion 1116A ismoved to the guide plate 202B above the introduction conveyor 1202.Consequently, the header portion 704 is made into a firm contact withthe guide portion 1202B and folded toward the main body 702 of thecarton 700. In the shrink packaging unit, the carton assembly 720 istransported through the covering portion 1204, the heat-sealing portion1206 and the shrink tunnel 1208 successively with the header 704 in afolded condition, so that shrink packaging is performed so as to formthe shrink-wrapped package 740.

The shrink-wrapped package 740 is transported to the corrugated boardcasing unit 1300 through the height arranging portion 1210 and the endarranging transporting unit 1212 successively and loaded in the emptycorrugated board box 600 by the product loading robot 1302 according tothe procedure shown in FIG. 126.

4-2-C Boxing Procedure 3

The carton 700 shown in FIG. 132, which accommodates two piece of theplastic case packed products and has the header 704 having the samewidth as the main body 702, will be explained below.

As shown in FIG. 142A, the carton 700 is discharged from the cartoner400 with the header 704 facing downward and transported by the firstconveyor 1102 of the carton arraying unit 1100.

The carton arraying unit 1100 rotates initial five cartons 700 by 180°by means of the first robot 1112 and places them on the second conveyor1104 as shown in FIG. 142B.

In the second conveyor 1104, as shown in FIG. 142C, five pieces of thecartons 700 are arrayed with the header 704 facing upward so as to formthe first carton group 722. The first carton group 722 is passed throughthe third conveyor 1106 and the fourth conveyor 1108 to the fifthconveyor 1110 and stopped by the carton arranging portion 1110B. Thefirst carton group 722 stopped by the carton arranging portion 1110B iscarried to the table 1110S by the carton pressing plate 1110J. If thefirst carton group 722 is transported onto the table 1110S, the pressingplate 1110J on the right side in the transporting direction is returnedto its original position thereby not obstructing transporting of nextfive cartons into the carton arranging portion 1110B.

On the other hand, as shown in FIG. 142D, the next five pieces areplaced on the second conveyor 1104 without being rotated by the firstrobot 1112, so that the five pieces are arrayed on the second conveyor1104 with the header 704 facing upward. In this way, the second cartongroup 724 is formed. The second carton group 724 is transported to thefifth conveyor 1110 through the third conveyor 1106 and the fourthconveyor 1108 and stopped by the carton arranging portion 1110B.

As shown in FIG. 142E, the second carton group 724, after stopped by thecarton arranging portion 1110B, is raised by the product loading robot1302 and next, rotated by 1800 around its vertical axis as shown in FIG.142F. Consequently, the header 704 of the second carton group 724 isdirected downward and located at a position opposing the header 704 ofthe first carton group 722. Next, as shown in FIG. 142G, the secondcarton group 724 is placed on the first carton group 722 by the productloading robot 1302 and the carton assembly, composed of 10 cartons 700,is formed at an end of the fifth conveyor 1110.

The carton assembly 720 formed in this way is pressed from both itsfaces by the carton pressing plate 1110J so as to form a neat shape andbrought upward by the product loading robot 1302 through both end facesand then, loaded into a corrugated board box at the corrugated board boxpositioning portion 1304.

4-2-D Boxing Procedure Example 4

The procedure for arraying and boxing the carton 700 shown in FIG. 138,which accommodate three pieces of the plastic case packed products andhas the header 704 on a side edge of the main body 702, will beexplained below.

As shown in FIG. 143A, the carton 700 is discharged from the cartoner400 with the header 704 directed in the transporting direction and in acondition that it is located forward relative to this paper in FIG. 143and transported by the first conveyor 1102 of the carton arraying unit1100.

As shown in FIG. 143B, the five cartons 700, after transported by thefirst conveyor 1102, are rotated by 180° by the first robot 1112 of thecarton arraying unit 1100 and placed on the second conveyor 1104 Suchthat the header 704 is directed in the direction opposite to thetransporting direction. As shown in FIG. 143C, of the five cartons 700,the initial four pieces are advanced on the second conveyor 1104 withthe header 704 located forward relative to this paper in FIG. 143 andarrayed so that the header 704 and the main body 702 overlap each other.On the other hand, as shown in FIG. 143D, the five cartons 700 arerotated by 180° around its vertical axis by the second robot 1114 whilethey are being carried by the second conveyor 1104 So that the header704 is directed in the transporting direction and located backwardrelative to this paper in FIG. 143. As shown in FIGS. 143E and 143F, thefourth and fifth cartons 700 are combined so that the header 704 of thefifth carton makes contact with the main body 702 of the fourth carton700 while the main body 702 of the fifth carton makes contact with theheader 704 of the fourth carton 700, thereby forming the carton assembly720.

Side faces of the carton assemblies 720 formed by the second conveyor1104 are arranged in line by the third conveyor 1106 and as shown inFIG. 143G, those carton assemblies 720 are transported to the shrinkpackaging unit 1200 by the third robot 1116 and shrink-wrappingpackaged.

The packaging system 2000 of the fifth embodiment is capable ofautomatically coping with the cartons 700 in which the quantity of theplastic case packed products accommodated inside thereof and theposition and size of the header 704 are different. If the sizes of themain body 702 and the header 704 of the carton 700 are different, thequantity and combination of the cartons 700 are often different. In sucha case also, this packaging system is capable of automatically formingthe carton assembly 720 by combining a predetermined quantity of thecartons 700 in a predetermined combination.

The carton assembly 720 is packed into a corrugated board box as it isin some case or shrink-wrapped and packed in a box in some case. In thiscase, this packaging system is capable of automatically separating acarton assembly which should be shrink-wrapped and the one which shouldnot after the carton assembly is formed by combining the cartons 700.

When boxing the carton assembly 720 or the shrink package 740, they needto be packaged in different patterns depending on the configuration andsize of the carton 700. In this case, this packaging system is capableof automatically coping with the aforementioned pattern.

Thus, the packaging system 2000 is capable of executing entire processincluding manufacturing of the plastic case packed product P by thewinding machine 900, manufacturing of the carton 700 by the cartoner400, formation of the carton assembly 720 or the shrink-wrapped package740 by the carton packing unit 1000 and packaging into the corrugatedboard box 600 sequentially. Therefore, a stock of the plastic casepacked products P on a process can be eliminated. Accordingly, theperiod up to shipment can be reduced largely.

Further, the film rolls R supplied to the winding machine 900 flowthrough the winding machine 900, the plastic case packed producttransporting supplying unit 800, the cartoner 400, the carton arrayingunit 1100, the shrink-wrapping unit 200 and the corrugated board casingunit 1300 without any deposit halfway and stored in the corrugated boardbox 600 as a plastic case packed product P containing the carton 700based on the principle “first-in first-out”. Therefore, it is possibleto specify which carton 700 or which corrugated board box 600 is loadeda specific film roll R situated at which position.

Accordingly, if any abnormality in terms of performance is found out infilms after they pass the packaging system and are packaged in acorrugated board box, the range of the cartons 700 or the product packedcorrugated board boxes 600 which should be collected and abandoned canbe specified with a small range. Additionally, if a trouble is found outin the market, it is easy to specify a problem by tracking itsproduction process.

1. A boxing apparatus, wherein a box body having folding portions, whichare developed to form a rectangular parallelepiped-shaped structure, andhaving an opening portion and a flap portion for forming a lid portionfor covering the opening portion at each of both ends thereof isconstructed from a folded state so as to form the opening portions, withthe box body having the opening portions held such that one of theopening portions faces upward while the other one faces downward, apackaging object is loaded into a main body of the box body through oneof the opening portions and the flap portions are constructed to formthe lid portion so that the packaging object is packaged in the boxbody, the boxing apparatus comprising foldable box body supplying means,opening forming means, box body holding means, packaging object loadingmeans, and lid forming means, wherein: the foldable box body supplyingmeans accommodates the box body in a folded state and supplies theaccommodated box body to the box body holding means one by one; theopening forming means constructs the box body supplied by the foldablebox body supplying means to the box body holding means from the foldedstate to form the opening portions; the box body holding means holds thefoldable box body having the opening portions f armed, with one of theopening portions f acing upward while the other one faces downward; andthe packaging object loading means loads the packaging object through anopening portion of the box body held by the box body supplying means;and the lid forming means folds the flap portions of the foldable boxbody after the packaging object is loaded by the packaging objectloading means, so as to form the lid for covering the opening portion.2. A boxing apparatus according to claim 1, wherein: the box bodyholding means comprises a rotation table which rotates around a verticalline while holding a box body at an outer peripheral portion so that theflap portions of the box body are located vertically with respect to themain body of the box body and transports the box body successively tothe opening forming means, the packaging object loading means and thelid forming means; and the opening forming means forms the opening inthe box body supplied to the rotation table by the box body supplyingmeans such that the flap portions are located vertically with respect tothe main body.
 3. A boxing apparatus according to claim 2, wherein thefoldable box body supplying means comprises a foldable box bodyaccommodating portion for accommodating the box body in a folded stateand a box body supplying portion for supplying the accommodated box bodyto the box body holding means one by one, the foldable box bodyaccommodating portion accommodating the box body in the folded statesuch that one of the folding portions is located downward and having apickup port for the box body which opens downward or obliquely downward,the box body supplying portion comprising: box body holding means forholding the box body and the box body holding means being capable ofapproaching/leaving the box body pickup port of the foldable box bodyaccommodating portion and the rotation table of the box body holdingmeans; and box body moving means for moving the box body holding meansbetween a box body pickup position for picking up the box body from thebox body pickup port and a box body loading position at which the pickedup box body is loaded on the rotation table, the box body moving meansincluding: a rotation shaft on which the box body holding means is fixedand which is provided obliquely with respect to a horizontal plane; androtation shaft driving means for rotating or pivoting the rotation shaftso as to position the box body holding means at either one of the boxbody pickup position and the box body loading position.
 4. A boxingapparatus according to claim 2, wherein the foldable box body supplyingmeans comprises a foldable box body accommodating portion foraccommodating the box body in a folded state and a box body supplyingportion for supplying the accommodated box body to the box body holdingmeans one by one, the foldable box body accommodating portion having abox body pickup port which opens toward the rotation table, the box bodysupplying portion including: box body holding means for holding the boxbody, the box body holding means being capable of approaching/leavingthe box body pickup port and the rotation table; and rotating means forrotating or turning the box body holding means around a vertical axis soas to position the box body holding means at either one of a firstposition opposing the box body pickup port and at a second positionopposing the rotation table.